Integrated production systemYour guarantee of reliability

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Step 1 Product design

At Sanko Kasei, because we specialize in engineering plastics, we are ideally positioned to provide a comprehensive product design service tailored to client requirements. We supply fully customized products created using leading product development solutions such as SolidWorks 3D CAD for design and ANSYS DesignSpace for structural analysis.
We also develop specific proposals for product designs or modifications based on client specifications.

Step 2 Mold design

Optimization of mold specifications is a critical process in the manufacture of plastic parts and components for the precision machinery, automotive and electronics industries.
At Sanko Kasei, we use CAE mold flow analysis prior to finalization of mold design to predict resin behavior from the filling stage through to curvature deformation after molding. This allows us to identify potential quality issues that can be addressed through further optimization of mold specifications.

Step 3 Mold manufacturing

Ultra-precision machining centers are used to create mold pieces, typically via direct carving of super-hardened material or electro-discharge machining. Machining is performed 24 hours per day to enable extra-fast turnaround for mold production.
Mold pieces are fabricated to exacting product specifications, typically on metal 3D printers, then painstakingly assembled, tested and adjusted to ensure optimum precision and accuracy.

Step 4 Trial moldings

A trial molding is performed using the newly assembled mold. The trial molding pieces are then analyzed to determine whether they satisfy the design specifications and client requirements, and also to assess consistency of quality on an ongoing basis.
Multiple production departments work closely with the client and subcontractors (where applicable) to ensure the highest standards of quality and workmanship.

Step 5 Measurement and evaluation

A 3D measuring system is used to carefully evaluate the trial moldings. At Sanko Kasei, the initial pre-production processes of product design and trial molding represent the foundations of the quality assurance regime that guarantees the highest standards of manufacturing and production quality.
A strong focus on technical analysis and evaluation at the pre-production stage helps to minimize the incidence of failures and defects at the post-production stage, while also allowing us to address potential quality issues at the early stage.
Our insistence on the best available technology is your guarantee of quality.

Step 6 Production moldings

Sanko Kasei has over 500 molding machines, from compact 15 t models for precision components to large-scale 850 t machines. This extensive equipment line-up is backed by an experienced workforce of technicians and engineers, including three injection molding engineers ranked Top Class, 16 ranked First Class and 118 ranked Second Class.
In addition to standard parts and components, Sanko Kasei offers a range of custom options such as high-performance resins, two-color molding, hoop molding, rotary molding, insert-outsert composite molding, clean room molding and extra-thin pieces.

Step 7 Machining and assembly

Machining and assembly cover the full range of secondary processes such as welding and printing as well as assembly of components, modules and finished products.
Many of these processes have been automated for greater efficiency and are performed by industrial robots.

Step 8 Inspection

The Sanko Kasei line-up of modern molding equipment is complemented by automated digital imaging inspection systems and other automated quality control systems that have been developed in-house. Specialization in individual processes further enhances the technical standards of each section.
The integrated production system at Sanko Kasei plays a pivotal role in maintaining the highest quality standards while minimizing costs and reducing lead times.

Step 9 Shipment

A modern server-client network supports seamless and efficient engagement through to the shipment stage in line with client requirements and expectations.