Product design

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Partnering with the client—design starts at the initial stage

Sanko Kasei boasts many years of experience in plastic molding and mold design and production. Using a combination of advanced design and analysis solutions such as 3D CAD, SolidWorks and ANSYS DesignSpace for structural analysis, we create and produce fully customized designs for new products and technical innovations.
Prototypes made on plastic 3D printers are used to evaluate and refine designs in the product design phase.
Sanko Kasei is a specialist in engineering plastics products. We engage closely with the client every step of the way to ensure that the final product meets their expectations and requirements.

3D CAD
solutions—SolidWorks, Unigraphics, TOPsolid

3D CAD is a design tool for generating three-dimensional models in a virtual space. It is extremely useful in automating the process of creating design drawings and technical documentation for industrial parts and products.
3D CAD allows us to examine molding shapes and designs in three dimensions. Designers can share their 3D CAD models with engineers and other experts for additional input.
Sanko Kasei uses the SolidWorks 3D CAD interface for consignment projects that involve structural design, development and/or flow analysis for new components.
Using 3D CAD, the design process becomes a collaborative enterprise where designers seek input from mold manufacturers and other technical experts while working closely with the client.

Structural analysis with ANSYSX DesignSpace

CAE analysis is a critical part of the design process for industrial components and products. It is used to evaluate early designs and identify potential problems and design challenges.
At Sanko Kasei, we use the ANSYS DesignSpace solution for structural and thermal analysis of new product designs. We also analyze client designs on a subcontracting basis.
Structural analysis of product designs allows us to identify potential issues, for example with strength or integrity, at the early stage. In this way, designs can be modified as necessary before production commences.

Furthermore, sections of the product deemed to play no role in terms of structural integrity or strength can be thinned out (given a more concave form) in order to minimize the overall weight as well as production costs.
This combination of product design and structural analysis enables Sanko Kasei to formulate design proposals with confidence.

Flow analysis with Autodesk Simulation Moldflow

Flow analysis involves simulating resin fill and flow behavior during injection molding.
Prior to computerized flow analysis, manufacturers were obliged to produce a series of prototypes that would be modified and improved through a process of trial and error. Needless to say, this was an extremely costly and time-consuming process.
These days, flow analysis is a key part of the design process that enables us to identify potential defects and problems in the molding process. We can now produce optimized designs much more quickly, including for complex and irregular shapes as well as relatively straightforward designs.
In this way, flow analysis helps to reduce the incidence of defects and abnormalities in the production phase. Higher-quality product designs can be transitioned into production more quickly, which means that products can reach the marketplace sooner.

CAE analysis can be used to optimize mold specifications for even the most complex designs