Production Technology
Nissen Chemitec Production Technology
Molding technology is a manufacturing method for processing and forming materials into a pre-determined shape. Products are formed by extrusion, injection molding, and other methods. This technology ensures product precision and uniformity and is applied to a wide range of applications, from mass production to custom products. It also plays an important role in many industries, such as automotive, medical devices, and packaging.
Production Technology Production Technology
for Automotive Products
Molding Technology
Foam Molding
- Feature
- Foam molding is a technology that generates bubbles inside a molded product using special plastic material to which a foaming agent is added. A key feature is that the thickness of the product is increased by the air bubbles, which enables increased rigidity, and the weight reduction rate is approximately 20% (arbitrarily controllable) compared to conventional injection molding. In terms of quality, the counter-press method is used to achieve good appearance quality. This molding technology has excellent environmental performance, contributing to improved fuel efficiency and CO2 reduction in mobility by reducing component weight.
Top Coat Application
- Feature
- Top coat application is a technology that joins resin molded parts and top coat material by placing the top coat material in the mold during injection molding. This technology enables various types of top coat with different textures and structures to be joined and it is more cost-effective than joining the material in a later process.
Processing Technology
Automation Initiatives
- Feature
- The jig-conveyor line shown in the photo is an excellent example of automation. Products move inside the machine on the jig, and robots perform the assembly operations. The introduction of the Jig-conveyor line has realized unprecedented manpower saving and production efficiency.
Automation of top coat wrapping
- Feature
- Among automotive interior parts, the process of wrapping plastic parts with top coat is particularly difficult. We have developed a high-quality wrapping process using our technology cultivated over many years, to supply products with a high level of customer satisfaction.
Painting process
- Feature
- Painting plastic parts can create a sense of luxury for interior parts. We have a coating process that specifically for a glossy finish, such as Mirror Black coating.
Multi-skilled Labor
- Feature
- One of the most indispensable labor-saving measures is the utilization of multi-skilled associates. We have adopted a production system which enables a single associate to complete all assembly processes, thereby saving labor and reducing defects between processes.
Development
Decoration
- Feature
- We are involved in the research and development of interior automotive products. The photo shows a decorative molded product that uses real materials (textiles, Japanese washi paper, etc.) to create a sense of luxury and depth that cannot be achieved with printed film. (For details, please refer to the link) (For details, please refer to the link)
Illumination
- Feature
- We also research and develop illumination parts for optical decoration. In particular, line illumination has become popular in recent years and can display light in a flowing manner and offer a variety of light effects with multiple colors. (For details, please refer to the link)
Special Manufacturing Methods
CVT(Clean Vibration Technology) Welding
This method involves irradiating the welding area with infrared rays to activate the welding interface and then joining while applying pressure and vibration. Flash formed by friction is greatly reduced, and even materials with high melting points such as LCP (Liquid Crystal Polymer) can be welded with ease. It can also be used for 3D shapes.
Ultrasonic welding
Ultrasonic welding uses high-frequency vibration to generate heat on the welding surface of materials. It is more energy-efficient than other welding methods and has lower operating costs. By using our uniquely designed welding section settings, the welding tolerance is minimized which maintain resistance to high pressure.
Gas Assisted Molding
This is a molding process that forms a hollow space in a molded product by filling the mold with inert gas after plastic is injected into the mold. This process can be used for general shrinkage, warpage control, and weight reduction with the hollow structure, and can also be used for molding plastic pipes. We have also established the technology for simultaneous in-mold hole punch on the outside surface of the pipe.
