When the system finally runs smoothly, after a long period of trial-and-error development, or when a customer praises the operation of a new product, that's when we feel all our work's been worth it. And that's when we feel the determination to do it again.

 

We developed all-electric servodrive injection molding machines to replace conventional hydraulic designs. In June 2000, we announced the 1400-ton all-electric model, offering the largest clamping force in the world, at the Plastic Show in Chicago. All-electric designs offer significant advantages over hydraulics, such as lower maintenance and running costs, and they have been increasing their share of the market recently worldwide. The remaining obstacle was to develop larger systems, and we met the challenge head-on by targeting a 1400-ton machine: the largest in the world. This larger scale can not only injection-mold large interior items such as automobile door trim, but also offers a significantly shorter cycle time. Our technology attracted considerable attention at the Plastic Show, with over 80,000 visitors from around the world. Even though it was not exhibited at the main site, we were thronged with people wanting to see the largest all-electric injection molding machine in the world, and taking snapshots in front of it. Our American salesmen were delighted to see their customers so happy. The MD series of all-electric servodrive injection molding machines is available in 650-, 850-, 1000- and 1400-ton models, and the No. 1 1000-ton unit was delivered to an automotive component manufacturer in Ohio. Sales are brisk throughout Asia as well, and our zeal is spreading to cover the world.





 




One successful application developed from these injection molding machines is the in-mold coating process, which coats the surface of thermoplastic products simultaneously with the injection molding process. Permolding the two processes simultaneously not only significantly reduces coating cost, but it is also an environmentally-sound technology because it used a special paint without organic solvents. The paint injected into the mold hardens instantly due the high temperature, assuring a smooth, beautiful finish unavoidable with conventional painting techniques.

 

Around 1995 one of our customers asked if it wasn't possible to mold plastic with a lower clamping force. To the engineer, being told something is impossible is like a challenge to find a way to accomplish it. Key people were collected from other sections in the heavy machinery division: machinery, electrical, materials. The idea they came up with was to move the press horizontally rather than in the conventional vertical direction. Their idea proved out, and low-pressure molding technology was born. But we still weren't satisfied. A new question emerged, whether or not the technology could be applied to enhance molding of work with combining materials. The mold is opened a fraction during the molding process, causing a temperature difference between the molded plastic and the skin material, significantly reducing skin material damage. This bold new concept, opening the mold, was embodied in our Dieprest molding technology, and earned the Best Technology Award of the Japan Society of Polymer Processing for its ability to preserve the soft touch of cloth and other high-grade materials. This technology has made a major contribution to improved surface quality of in-mold laminates, and we are working to develop further applications now. We don't just answer the customer's question, we discover the answers to a host of questions no-one has thought of yet. That's the Ube "CAN-DO" spirit.
 
About The Aoki Katashi Best Technology Award
 

Industry is demanding lighter and less ex-pensive parts in every field, especially automobiles, and Ube Machinery Corporation has developed the New Rheocasting process to answer their needs with lightweight components offering excellent strength and pressure resistance. Light metals in a semi-solid state are slowly filled into the casting mold in this process, maintaining uniform composition to improve work strength to the level of forged pieces. This process is expected to find application in the casting of key automotive components, where high-grade manufacturing is essential. When steel parts are replaced with lighter alloys in automobiles, the lighter weight makes a major contribution to the pre-servation of the global environment by improving mileage and reducing emissions. If high-strength alloys could be used, it would become possible to vastly expand the range of utilization of these lightweight materials. This has been a continuing research theme at Ube Machinery Corporation. Perfected after more than five years of R&D, we are confident that this process is one of the most advanced in the world, joining our field-proven squeeze casting technology. It is a proud moment when a process we developed spreads across the world, contributing to the preservation of the global environment.