Company Introduction Taisei Kogyo Co., Ltd.

Company Introduction Taisei Kogyo Co., Ltd.

Company Introduction
Taisei Kogyo Co., Ltd.
26-1 Ikeda-kitamachi, Neyagawa, Osaka
PHONE : +81(0) 72-829-3588
FAX :+81(0)72-827-3390
TAISEI
about us
Location: HQ; Neyagawa, Osaka
Research Lab; Higashiosaka, Osaka
Thailand Factory;
Products: Manufacture and assembly of plastic parts
Manufacture of metal injection moulding (MIM)
Manufacture & Assembly of Plastic Parts
- Leading the technologies of plastic injection
- Materials
- Metal mould
- Automation
Research and Development of Micro Metal Injection Molding Process
Manufacture of MIM Parts
- Leading the technologies of metal injection
moulding
- Materials
- Metal mould
- Debinding and sintering
2
about MIM
TAISEI
Powder Metallurgy
Metal Powder
Kneading
Binder
Plastic
Injection Molding
MIM Pellet
Pelletization
MIM
(Metal Injection Molding)
Compacted
Injection Molding
Debinded
Debinding
Sintered
Sintering
Advantageous method for mass production of complex shape and processing resistant materials
Research and Development of Micro Metal Injection Molding Process
3
Our product overview
Cam
SUS316L
Nozzle
SUS630
TAISEI
Propeller
Ti-6Al-4V
MIM Features
 Mass production of complicated shape
 Reducing the amount of parts for assembly
 Better cost performance
 High melting point material production
 Less limitation of the metal material compared with other methods
 Composite structure of dissimilar material is available
Research and Development of Micro Metal Injection Molding Process
4
Adaptable Material
Stainless Steel
310 (25Cr-20Ni)
316L
317J1 (18Cr-16Ni-5Mo)
410L (13Cr)
630 (17Cr-4Ni-Cu-Nb)
Nickel Alloy
Soft magnetic material(Fe-Ni)
Nickel-Titanium Alloy
TAISEI
Titanium and Titanium Alloy
Pure Titanium
Ti-6Al-４V
Copper and Copper Alloy
Pure copper
Nickel, Cupro-nickel
Nickel Silver
Tungsten Alloy
W-Cu
Research and Development of Micro Metal Injection Molding Process
5
TAISEI
Our Japanese lab
 Trial production of new materials
 High precision 3D measurement
using ATOS system
 Simulation analyses
X-ray computed
3D optical
tomography scanner measurement system
Research and Development of Micro Metal Injection Molding Process
Micro injection
machine
Rheological flow
simulation
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TAISEI
Product overview and our target
1mm
Hitherto known MIM
The world smallest
mass producible
steel gear
Optical connector
Rice grain
Impeller
Dimensional precision
100µm
1cm
Cam
1mm
1µm
5mm
(φ0.3mm 0.005g)
Micro MIM
1mm
Reactor
Micro forceps
0.01µm
Planetary wheel
1µm
10µm
100µm
1mm
1cm
MIM product size
Research and Development of Micro Metal Injection Molding Process
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TAISEI
Our research target
1. Invent new material MIM process
2. Develop brand new processes
3. Challenge to tighter μ-MIM processes
Actuator
Catalyst
Micro Gears
Soft magnetic material
Electrode
Porous structure
Medical
Heat sink
Non ferrous alloy
Combined material
Research and Development of Micro Metal Injection Molding Process
Forceps
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TAISEI
Use of
Plastic mould
Research and Development of Micro Metal Injection Molding Process
What is “SPiMIM” process ? (Sacrificial Plastic-mould insert MIM) TAISEI
The use of lost form technology is effective to overcome the issues of µ-MIM production
Sacrificial plastic mold (SP-mould)
Manufacturing
SPiMIM can improve…
 Filling,
 De-molding,
Metal injection molding (MIM)
 Handling.
into the SP-mould
As the results
Debinding / Sintering
to remove the SP-mould
SPiMIM can produce…
 Tiny,
 3D complex,
 Fine structured parts.
MIM products
Research and Development of Micro Metal Injection Molding Process
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Examples of SPiMIM Products
TAISEI
Optical fiber connector
Micro impeller
Micro reactor
Plastic injection molding
Rapid plot-typing
Lithography
Made of PMMA
Over-molded
200μm
Debinding and sintering
Hollow, Under-cuts & Screw
3D closed structure
Research and Development of Micro Metal Injection Molding Process
Micro structure
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Examples of Sintered Parts Manufactured by Resist / µ-SPiMIM
Ni-form (Reference)
3µm 316L powder
TAISEI
9µm 316L powder
100μm
100μm
100μm
m
100
50µµm
50µm
50μm
Fine powder shows the better transcription than coarse ones.
We can manufacture hundreds micron sized structures.
However we tried to manufacture the smaller sized structure.
Research and Development of Micro Metal Injection Molding Process
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TAISEI
Use of
Nano powder
Research and Development of Micro Metal Injection Molding Process
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Use of Smaller Powder in MIM
TAISEI
Fine powder is generally used for the quality improvement of MIM product.
Good
 Lower sintering temp.
 Smaller grain size
 Higher dimensional accuracy
 Smoother surface
Particle size
 Higher oxidation
 Lower packed density
 Higher viscosity
 Higher cost
Nano
Micron
700 nm
Bad
10 µm
50 µm
Research and Development of Micro Metal Injection Molding Process
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SEM Images of Micro-structured Parts (5µm L/S pattern)
Green compact
Sintered part (573K)
TAISEI
Sintered part (973K)
10µm
The size of line and space structure became smaller,
we could obtain sintered parts with comparatively high transcription.
Research and Development of Micro Metal Injection Molding Process
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Comparison: Size of Micro-structured Parts
300µｍ
200µｍ
Germany
(80W-20Cu)
100µｍ
TAISEI
50µｍ
100μm
Korea
(W-Cu)
LIGA/µ-SPiMIM
(SUS316L)
500
Resist/µ-SPiMIM
(SUS316L)
Height (μm)
400
Sumitomo
Electric
Industries, Ltd.
300
(PZT)
50µｍ
Singapore
AIST
(SUS316L)
200
Only
5µm
100
0
-200
NIL/µ-SPiMIM
(Cu)
-100
0
100
Width (μm)
Research and Development of Micro Metal Injection Molding Process
200
10µm
Probably, this MIM parts would be minimumsized structure. 16
Micro Metal Injection Molding Machines
Mixing Machine
Thermo Haake GmbH
MiniLab Micro Rheology Compounder
TOYOSEIKI Co.LTD
RABO PLAST MILL
Research and Development of Micro Metal Injection Molding Process
TAISEI
Micro Injection Molding machine
Battenfeld GmbH
Micro System 50
RAMBALDI Co I.T. Srl
Babyplast 6/10
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ATOS Triple Scan Deformation Analysis
TAISEI
Using the ATOS Triple Scan and comparing it to the CAD Data,
we are able to spot any possible deformation that may have
happened during production.
-Reduce production start-up times
-Optimize component quality
-Speed up the time to production
Research and Development of Micro Metal Injection Molding Process
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Micro-Xray CT
TAISEI
SEM image
1mm
CT image
Research and Development of Micro Metal Injection Molding Process
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Injection Molding Simulation
TAISEI
Core Tech（Taiwan)
For Micro Gear
Investigate
1mm
Research and Development of Micro Metal Injection Molding Process
Simulation
TAISEI
contact analysis
engage analysis (fitting)
motion simulation
Research and Development of Micro Metal Injection Molding Process
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TAISEI
about
Porous Metal
Research and Development of Micro Metal Injection Molding Process
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Pore size
TAISEI
Product size
Research and Development of Micro Metal Injection Molding Process
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Porous Metals
TAISEI
①PSH- Method
②FSH-Method
③MIF-Method
④FDB-Method
SUS,Ni,Cu
SUS, Cu, Ni, Au
Ti,SUS,Ni,Cu
Ti,SUS,Ni,Cu,Al
Research and Development of Micro Metal Injection Molding Process
Thank you
MICRO-MIM
THE KEY TO SUCCESS