Mold processing solutions optimized by Japanese Quality x Vietnam Production

Technology & Services

Optimizing Mold Processing Solutions with Japanese Quality x Vietnam Production
■Mold processing is a culmination of multiple processes.
1. Machining (High-Speed Cutting)
→ A process that determines the "surface and shape accuracy" which forms the foundation of the cavity shape.
2. Wire EDM
→ High-precision processing of precise split shapes such as core/cavity inserts and slider components.
3. Electrical Discharge Machining (EDM)
→ Capable of processing "deep shapes in steel materials" and "fine features" that are difficult with machining, even in high-hardness materials.
4. Polishing and Finishing
→ The most crucial process that affects surface quality for aesthetic parts, etc.
5. Assembly and Adjustment
→ Influences mold operation verification, precise clearance adjustment, and optimization of molding conditions.
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■Three Key Points for Successful Mold Processing
1. Precision (Dimensional Control in Micrometer Units)
→ Directly linked to dimensional stability and fitting accuracy of molded products.
2. Surface Quality
→ Affects the aesthetics of appearance parts and the finish after painting.
3. Processing Considering Cooling Efficiency
→ The most critical factor determining cycle time during mass production.
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■Muto Vietnam's Mold Processing "Strengths"
◆ Strength ① | 119 Mold Processing Specialists In-House
• Specialized technicians assigned to each process, from machining, wire EDM, electrical discharge machining, polishing, to assembly.
• Large workforce enables handling of short-delivery projects.
• Accumulated processing know-how based on experience.
◆ Strength ② | High Equipment Capability (Possessing numerous high-precision processing machines)
• High-speed Machining Centers
• Wire EDM Machines
• Electrical Discharge Machining Machines
• Precision Polishing Machines
• 3D Measuring Machines
→ Achieves mass production capability for high-precision molds and stable quality.
◆ Strength ③ | Optimizing "Processing Accuracy" through Integrated Operation with Molding
Instead of processing solely within the mold processing department,
on-site feedback from 196 molding personnel is directly reflected in the design & processing stages.
• Gas venting during molding
• Sink mark countermeasures
• Dimensional stability
• Cooling efficiency
• Improved mold release
These "problems that actually occur in mass production" can be prevented from the processing stage.
◆ Strength ④ | Processing Design that Considers Secondary Processing and Assembly
In-house,
• Painting (154 personnel)
• Printing (51 personnel)
• Laser (7 personnel)
• Assembly (177 personnel)
are available, allowing "all processes" to be considered at the mold processing stage.
→ Enables mold processing that can prevent appearance defects, printing misalignment, and assembly fitting defects.
◆ Strength ⑤ | Japanese Quality + Cost Optimization through Overseas Production
• Inheriting the mold technology of Muto Seiki Japan
• Technical guidance and quality standards are also Japanese style.
• Optimizing costs through Vietnam production
→ Achieves both "Japanese Quality x Vietnam Cost".
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■Mold Processing Challenges → Muto Vietnam's Solutions
● Challenge ①: Unstable processing accuracy (Frequent mold troubles)
→ Solution: High-precision processing equipment + dimensional control by skilled personnel
• Micrometer-level precision control
• Clearance adjustment during mold assembly also handled in-house.
● Challenge ②: Numerous outsourced processing, resulting in inconsistent quality and delayed delivery
→ Solution: Nearly all processing steps completed in-house
→ Zero quality differences from outsourcing, information transfer loss, or transportation delays.
● Challenge ③: Time-consuming modifications after prototyping
→ Solution: Immediate adjustments possible due to adjacent molding department
→ Enables the fastest loop of prototyping → modification → re-trial.
● Challenge ④: Unstable "surface quality (polishing)" for appearance parts
→ Solution: In-house polishing and finishing process specialized for appearance parts
→ Supports high-aesthetic parts such as camera components and automotive interiors.
● Challenge ⑤: Long cycle times due to insufficient mold cooling during mass production molding
→ Solution: Water channel processing and EDM finishing considering cooling efficiency
→ Leads to shorter cycles and reduced mass production costs.
● Challenge ⑥: Defects occurring during secondary processing or assembly
→ Solution: Processing design with thorough knowledge of painting, printing, and assembly lines
→ Enables overall quality optimization across all processes.
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■ Reasons to Choose Muto Vietnam for Mold Processing
・ 119-member specialized processing team
・ Possesses high-precision processing equipment in-house
・ Integrated system from design to processing, molding, secondary processing, and assembly
・ Feedback of molding site knowledge to the processing stage
・ Strong in surface quality for appearance parts
・ Optimal balance of Japanese quality and overseas cost
・ A "mold factory" that can control delivery time, quality, and cost entirely.