Core Technologies|SANWA SCREEN CO., LTD.

Core Technologies

New decoration techniques, created from a determined challenging spirit. Techniques that achieve assured quality and excellent cost performance by combining these in-house developed technologies. SANWA’s core technologies enable manufacturing with a high degree of freedom utilizing the refined sense of people.

Core Technology01

Film Insert Molding

This is a manufacturing technology in which silk screen printed film is inserted into an injection mold, and then resin material is injected into the injection mold to create an integral mold with the film. This simultaneous decoration and molding process enables us to produce even such things as large parts and products with a complex curved shape. It is a technology of SANWA’s unique expertise, which enhances the technical capabilities in mold film printing, resin injection molding and other processes beginning with the design and manufacture of molds. The technology has the greatest potential for future manufacturing in the home appliances industry and automotive industry that requires a high level of design and sense of quality along with functionality.

Core Technology02

Two-color Molding

A technology in which different types of resins or resins with different colors are simultaneously injection molded to produce a single finished product. During two-color molding, two molds are used. Each of these molds requires high-precision in addition to proficient skill for setting molding conditions. We have installed an 800-ton two-color molding machine, a machine seldom used in Japan to support the manufacture of large parts. Also, when using film insert molding with two-color molding, the production process becomes significantly more complex, which is a major strength in increasing our competitiveness.

Core Technology03

Vapor Deposition and Sputtering

Vapor deposition and sputtering technology is decorating resin material with a metallic texture. A very thin layer of metal on the nano-level is formed on the molding material inside a machine with a vacuum. This adheres to the surface of the resin molded part. It is a delicate technology affected by the external environment so the manufacturing environment must be strictly controlled. We identify whether vapor deposition or sputtering is the best method based on the required characteristics of the product before incorporating it into the process. This technology, which gives beautiful polished and glossy appearance to light flexible molded parts, is often used for car emblems, said to be the face of the vehicle. We hold a large share of the market with the support of automobile manufacturers around the world.

Core Technology04

Transparent Resin Decoration

Transparent resin decoration utilizes resin material with a clear texture. This is a technology with very strict conditions that does not allow foreign material within the resin or even the smallest defect. It is often used in two-color molding and SANWA takes pride in producing parts with beautiful transparency, therefore we conduct thorough quality control in a detailed manner. This technology enables us to provide products with even greater design and deeper expression.

Core Technology05

High Added Value Painting

A special feature of SANWA is that we have advanced painting technology with high added value. We have various technologies including piano-black painting, clear painting, high-brilliance painting, and mask painting. Among these technologies, piano-black, which features a beautiful glossy and high-grade appearance, is a painting technology that has gained much attention in other areas besides the automotive industry. Since even the smallest amount of dust floating in the air can cause a defective product, we tightly control the process in conjunction with humidity control or such other factors.

SANWA’s Original Technology

SANWA enables manufacturing that feels almost made-to-order by combining the various processes with the experience and knowledge of our engineers based on our core technologies. Major and minor technologies obtained through a number of innovations by each of our engineers have been handed down within our company as unique expertise that cannot be imitated by others. We reliably produce good expressive products in mechanized factories as though they were entirely crafted by hand. This is what leads to SANWA’s originality.

SANWA’s Processing Capabilities to Achieve Core Technologies

  • Screen printing

    [Cylinder press/Semi-automatic printing machine/Mold printing machine]This process has been used since our founding. The principle is that the ink placed on a stencil (screen mask) woven with synthetic fibers such as polyester and nylon is extruded using a spatula-like squeegee through fine holes and deposited onto a film.

  • Thompson machining

    It is a process to cut the required shape of the film using a mold with blades called Thompson blade.

  • Press

    A press machine is used to form various shapes in processing such as cut, bend, forming, etc. It is also possible to process resin film or metal.

  • Injection molding

    [Film insert molding/In-mold molding/Two-color molding and transparent material molding/Other general molding]It is most often used molding method to manufacture plastic products. The particle of the resin, referred to as pellets, melted in a heating cylinder is injected into a mold by a screw and then molded and cooled. Two types of resin can be molded at the same time.

  • Painting

    [Robot painting/Spindle painting]Mostly used in plastic molding decoration. It is an atomized way of spraying paint mist by using air. Robot painting is also called spindle painting which paints while rotating the product.

  • Laser processing

    We have a YAG laser machine and a CO2 laser machine. The YAG laser machine is a device for removing paint films of painted plastic products in decorative design shapes. It is used mainly in manufacturing of products for transmitting light of illumination devices. The CO2 laser unit is mainly used for cutting shapes from resin molded articles.

  • Vapor deposition

    By heating the metal material in a vacuum, the gaseous metal forms a metal film on the surface of the plastic molding. It is also possible to achieve a half-mirror finish by reducing the film thickness.

  • Sputtering

    A process of skipping metal atoms rely on plasma and argon to the target metal material in a vacuum, causing a metal film to adhere to the surface of a plastic molding. It offers stronger adhesion and thinner film thickness than vapor deposition.

  • Potting

    This is a process of putting a special transparent resin on top of a printed film or metal plate. In the technology used for emblems etc., it gives a three-dimensional feeling to the nameplate. Material used is lead-free, environmentally-friendly resin.

  • Ink-jet printing

    Uses ink that can be used for plastic moldings and prints in the same way as with general ink-jet printers. It is possible to print design data directly. Small lot printing and simultaneous multi-color printing are also possible.

  • Hot stamping

    It is a process of transferring design to molded products using the deposited printed film or metallic film. It can be applied onto a molded part’s surface that is not flat. This is difficult in silk screen printing.

  • Pad Printing (tampography)

    It is a process of printing by transferring the ink on a metal plate to an elastic silicon pad, and then perform the following transfer to the surface of molded articles. While being on the pad, the principal solvent volatilizes and makes printing possible.

Processing Capabilities

 

Screen printing

Thompson machining

Press

Injection molding

Painting

Laser processing

Vapor deposition

Sputtering

Potting

Ink-jet printing

Hot stamp

Pad printing

Mold manufacturing

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