Business
Nagatsu designs and builds precision molds for plastic injection molding, and uses those molds for volume production, from molding through painting, printing, and assembly. We also take orders for just a mold, or just the repair or transfer of a mold made by another company.
Mold Design & Manufacturing
We design and build molds with stable molding quality in volume production as our first priority. We draw fully on our own volume-production experience and apply that know-how down to the finest details. Mold tryouts are also run in-house on actual molding machines, so we can verify results and feed them back into the mold.
We are strong in complex structures, and deliver molds that run smoothly in volume production even for highly demanding molded parts.
- High performance and durability
- From complex geometries and precision parts to high-cycle, multi-cavity molded parts, we respond with design capability that combines mold mechanisms, accuracy, and machining technology.
- 1 µm-level correction
- Molded parts shrink and deform. We predict deformation with flow analysis, build it into the mold design, and correct the mold in 1 µm increments based on measurement data. Even for parts that demand high dimensional accuracy and roundness, such as lens barrel components for cameras and projectors, we build molds that mold consistently in volume production.
- From analysis to final polishing
- We analyze cooling, filling, packing, and warpage with flow analysis software before designing, then machine on 5-axis machining centers and EDM machines, measure during machining, and finish-polish under a microscope, completing each mold in a single continuous process.
Volume Molding, Painting, Printing & Assembly
Beyond building molds, we also handle volume production, from molding through painting, printing, and assembly. In addition to volume molding in a wide range of materials, from super engineering plastics to commodity resins, we take on processes that add value to molded parts, such as multi-material molding and secondary processing.
Our mold-making know-how is applied to volume production, and what we learn in volume production is fed back into mold making. This is where Nagatsu's strength lies.
- Molding know-how
- Because the team that designed and built the mold also runs volume production, we can adjust molding conditions and solve defects all the way back at the mold.
- Range of materials and processes
- We work with materials from super engineering plastics and commodity resins to magnesium alloys. In addition to injection molding, we offer two-shot molding and insert molding.
- Volume production at three overseas factories
- We run volume production with a total of 95 injection molding machines at three factories in China (Dongguan and Wuxi) and the Philippines. The Dongguan factory has a spindle painting line and handles painting, printing, and sub-assembly.
Ultra-Precision Machining
We manufacture mold inserts for optical elements such as lenses, as well as ultra-precision parts that require nanometer-level accuracy. Our vibration-isolated, temperature-controlled booths enable stable ultra-precision machining. We assure quality through precision measurement on a variety of ultra-precision measuring instruments, including UA3P and Zygo. We can also provide inspection and measurement data.
We also take part in industry-academia projects to develop nanometer-level ultra-precision molds, working on research and development of advanced technology (joint research with the University of Tokyo, Chubu University, and RIKEN).
- Machining environment and equipment
- We machine in vibration-isolated, temperature-controlled booths on UVM-450C and ULG-100D ultra-precision machines. In 2013, we installed a nanometer-level machining room in the Head Office Factory.
- Ultra-precision measurement and data submission
- We measure on a variety of ultra-precision measuring instruments, including UA3P and Zygo, to assure quality. We can also provide inspection and measurement data.
- National projects and joint research
- Commissioned three times (2003, 2006, and 2009) by the Ministry of Economy, Trade and Industry for projects to develop nano-machined ultra-precision molds. We conduct joint research with the University of Tokyo, Chubu University, and RIKEN.
Mold Tryout & Low-Volume Production
High-performance measuring equipment that verifies submicron-level machining accuracy supports our precision and quality. With five in-house molding machines for trials (clamping force 15 t, 50 t, 75 t, 100 t, and 180 t), we run test shots as soon as a mold is finished and shorten the time to volume-production launch. Low-volume production is also available.
- Measuring tryout parts
- We verify the dimensions of tryout parts on measuring machines that confirm submicron-level accuracy, such as the Crysta Apex CNC coordinate measuring machine and the VR-5200 one-shot 3D profile measuring system.
- Evaluation prototypes and low volumes
- We also handle prototype tryouts for pre-production evaluation and low-volume production.
Mold Repair & Maintenance / Transfer of Molds Built by Other Makers
We repair and maintain molds we have delivered, and we also repair and maintain molds built by other makers. Regular maintenance extends mold life and leads to stable molding. We carry out appropriate repair and maintenance using the knowledge gained from mold design and manufacturing.
- Molds built by other makers
- Whether a mold was built by Nagatsu or by another maker, we check its condition before repair and maintenance.
- Regular maintenance
- Regular maintenance extends mold life and leads to stable molding.
- Measuring shapes from the actual part
- We can measure the shape of the actual part with a 3D scanner. Even for molds and parts with no surviving drawings, we measure the real thing and use the data for repairs.
Product Development & Consultation
With both a volume-production perspective and a mold-design perspective, we offer proposals that achieve both production efficiency and added value in molded parts at a high level. Whether it is "Can a mold make something like this?" or questions about mold design, maintenance methods, or repairs, feel free to consult us about anything related to molds. We also respond quickly to urgent requests.
- Responsiveness
- We address the problems that arise during product development with knowledge that spans design through volume production. We also respond quickly to urgent requests.
- Verify by analysis before building
- We analyze cooling, filling, packing, and warpage with flow analysis software, then verify molding concerns and make proposals.
- Experience with parts for different applications
- We make proposals based on knowledge gained from parts for a range of applications, including optical parts, automotive parts, medical parts, and micro-machined parts (decorative parts).
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You can consult us even before you have a drawing. We can also sign an NDA first.