Examples of Processed Products

Plastic shaft bearing with a deflection tolerance for the internal and external diametesr of 0.005mm

Usage Bearing shaft for OA equipment
Material Acetal(POM)
Die 4 cavity
Reason of development New application
A customer had used a machining process in the early stage of development, and later used a wet polishing process. However, they were struggling to meet the specifications, even during this development stage. Nichiei received inquiries from them and recommended using an injection molding process. The part was made from acetal (POM), a crystalline resin that has a high post-molded shrinkage rate, something that was unacceptable to the customer. To solve this problem, we worked with the customer to produce a machine that could measure molding tolerance precisely, and observed the variation over time 1 month, 3 month, 6 month and 1 year after molding. After confirming that there was no change in dimension, mass production was started. Based upon the volumes required, Nichiei built a 4-cavity tool with a tolerance of 2u-3u, supporting the mass production of 300,000 bearing shafts per month.

Thick-walled bearing shaft: Coaxiality tolerance of 0.01mm

Usage Bearing shaft for OA equipment
Material Acetal(POM)
Die 1 cavity
Reason of development Replacement of a machined part to improve quality
A customer had used a machining process to meet the specifications in the early stage of development. The process was time-consuming, costly and yields were low due to quality issues. Nichiei was contacted by the customer and recommended injection molding. A major concern for this part was the fact that it was thick-walled, which often leads to a surface indentation, or "sink mark", due to material shrinkage during cooling. In fact, molding this part with a coaxial tolerance of 0.01mm was extremely challenging, but Nichiei was able to solve all the problems, producing a blemish-free part which is now in full commercial production.

Plastic bearing shaft: Circularity of 0.002mm ; External diameter tolerance range of 0.008mm

Usage Bearing shaft for OA equipment
Material Liquid Crystal polymer(LCP)
Die 4 cavity
Reason of development New development (trial production)
A customer was struggling to achieve tight tolerances in a molded part requiring circularity of 0.002mm and an external diameter tolerance of 0.008mm. Nichiei offered a proprietary molding methodology that is now meeting both the performance and specification requirements, resulting in a very satisfied customer.

Insert gear of JGMA Grade 0

Usage Gear for OA equipment
Material POM, elastomer
Die 4 cavity
Reason of development Next generation design to eliminate noise during operation
A customer realized they needed a plastic gear to reduce the noise in their Office Automation equipment. Since plastic alone would not meet the high temperature requirements of the part, it was suggested that they include a metal component within the plastic gear. However, a metal/plastic insert molded gear typically does not maintain the tight co-axial tolerance required for a JGMA Grade 0 gear. The customer came to Nichiei who then developed a new (patented) molding technology to produce an insert molded gear that maintains the necessary accuracy and dimensional stability, while meeting the fitness-for-use requirements of the part.

Super small module gear

Usage Gear related to a cell phone
Material PEEK
Die 1 cavity
Reason of development New development
A manufacturer in the cell phone industry designed a super-small module gear, but since the teeth were very small and a torque was applied to the gear, typical engineering plastics would not work. Nichiei recommended a suitable material to the customer, based on our knowledge of performance needs and conditions of use, plus over 20 years of experience with super-engineering plastics. Also, since this was such a small part, gate placement and use of ejector pins required special knowledge.

Pipe with an internal diameter of φ0.5 and the length of 72 mm

Usage Medical component
Material PES
Die 1 cavity
Reason of development New development(Trial production)
A customer needed a funnel-shaped end for a clear pipe with an internal diameter of φ0.5 and length of 72mm. Since burring could not be tolerated, the customer could not have the part machined from rod stock. Nichiei was asked for advice and began the development process. Since the injection pressure was very high, it was extremely difficult to keep the mold pin of φ0.5 standing straight during molding. Also, the length of 72mm was nearly impossible to achieve with injection molding. As a result of much trial and error, Nichiei has been able to produce parts with the necessary degree of precision.

Super small gear

Usage Small Screw
Material PEEK, etc.
Die 1 piece
Reason of development Trial production
Nichiei manufactured this part to meet a customer’s need to replace an extremely small metal screw with a plastic screw. The screw was so small that typical engineering plastics did not satisfy the required strength of the screw thread. Nichiei worked with the customer to recommend the appropriate material(s), design and build the tool, and produce prototype parts.

Various super engineering plastic parts

Usage Various
Material PEEK, PI, PAI, PBI, etc.
Die 1 cavity
Reason of development -
Nichiei has approximately 20 years of experience in the micro-molding of super engineering plastics, manufacturing various parts requiring very high tolerances. Specifically, Nichiei has manufactured many precision products in PEEK, PI, PAI (Torlon®) and PBI (Celazole®), all utilizing challenging, often proprietary molding technologies. Applications have included bearing retainers, trochoidal pump components, material handling parts for a clean room environment, and components requiring high strength, heat resistance and good tribological properties. When super engineering plastics substitute for metal in automotive components, they enable weight reduction, fuel efficiency and a lower carbon footprint. In addition, plastic gears have been shown to improve the efficiency of automotive transmissions, compared to their metal counterparts.