Factory tour until Lego's Reprint Helmet is molded
I came to a factory where a reprint helmet is molded
The president who runs the mold manufacturing company who made the chance to remake the knight's helmet invited me to the factory.
I got photographing permission in the factory, so I would like to report on how the mold can be made at the factory and advance to molding.
I visited the mold manufacturing factory in Shimane Prefecture of Takumi Engineering Co., Ltd.
In addition to this, it is a company that owns three factories in Saitama Prefecture including Tokyo Headquarters Shinjuku.
In this company, we manufacture a wide variety of molds, such as automotive parts, mobile terminals, caps for PET bottles, casings for weak electric appliances, and other varieties.
And this company also manufactures precision rubber parts and molds resin parts, including making test pieces and checking mold making.
Many machines were lined up in the factory, and I did not consider what machines do what.
However, when the president took me around the factory, they taught me the characteristics of each machine.
Machining center with amazing machine precision and high speed excavation
First, the machining center.
Machining center is a machine that drills metal clumps with a drill bit.
In this factory, YBM 950 V was also installed in addition to the YBM 640 V made by YASDA shown in the picture.
The numerical value of 950 in this machine model expresses that it can move 900 mm in the horizontal axis direction and 500 mm can move in the vertical axis direction.
In other words, it is a machine that can drill a very large mold at high speed.
I feel that this machine is too big to make small items like LEGO.
However, when manufacturing dies for mass production and molds for molding large parts, they are going to shave out with such a machine.
Parts molded by combining multiple molds called "pieces"
I saw a mold drilled by a machining center and an electric discharge machine.
The helmet is sandwiched between upper and lower pieces.
In addition, there is a piece for making space inside the helmet, you can see that it consists of a total of three pieces.
Compare gap of parting line
To mold this helmet this time, we asked you to measure the actual thing and made the mold with 1/1000 mm working accuracy.
However, at the time of factory tour, there was a gap of the extent that it was caught by the nail.Perhaps there is a gap of about 1/100 mm.
At a later date, we asked for adjustment of these pieces and we decided to set up the guide pins so that the top and bottom frames fit perfectly.
With this, it seems that the gap has become invisible, with accuracy equal to or higher than the LEGO helmet of 40 years ago.
Photo right gray helmet, 1978 made 375 Yellow castle helmet at that time.
The left beige helmet is the one of the reprint version which was molded in prototype this time.
Both helmets have a mold parting line in the center.
This photo is a state of a helmet molded without setting guide pins yet.
At this point, it has almost the same molding precision.
Each time we try to improve the precision of molding, we need to consider more effort and method of designing the mold and the cost will rise.
Therefore, it is necessary to make it while considering the balance with cost.
Since Takumi Engineering Co., Ltd. has technological expertise cultivated through cell phone cases and precision part molding, etc., Takumi eng. are making it with expectation of resin shrinkage, warping and shrinkage rate accurately.
I can understand that this company is contracted only for jobs with high request accuracy.
Continue from the factory tour, please wait for the next content again.