Grinding machine operationsThe grinding machine is used to grind the surface of molds with tolerances of 1/1,000 mm. Expe-rienced operators can use grinding machines to remove just the thickness of the ink markings from the surface of the mold. Surface finishing workThis work involves polishing the surface of molds processed by the machining center. As shown in the photo at the bottom left of page 6, this is performed manually, with meticulous attention to detail, using a scraper. A microscope is used to detect even the slightest imperfections in the polish.Machining center operationsOperations using the machining center are crucial for shape processing in mold manufacturing. Molds are processed using tools attached to the tip of the main shaft of the machining center. For molds used to produce product surfaces, meticulous manual polishing is required to smooth out the cutter path.Work on an electrical discharge machineElectrical discharge machining involves melting surfaces with an electrode to process fine holes and grooves that can’t be machined using the machining center. In addition to cutting, this electrical discharge machine can be used to create fine emboss patterns (fine grain textures) on products.Mold design that takes cost and durability into considerationsection consistently meets high technical standards.“Since we three are responsible for all processes from design to machining, each of us has to be skilled in every process to produce molds in a timely manner,” says Murata. “I think gaining multi-faceted skills, knowledge, and experience is essential to produce quality molds consistently.”Other factors need to be taken into account when making molds. Rion’s products are known for their long lifespans; many old molds made decades ago remain in use today. Considerations related to use for many years, including ease of maintenance and resistance to soiling and wear, are also important.“Rather than prioritizing cost reductions during production, which results in a mold that lasts just five years,” explains Ozawa, “we’d like to choose a mold that lasts 30 years, even if it’s slightly more expensive.”Finally, Ozawa described the unique joy of the mold-making job. “I feel a sense of fulfillment whenever I get to witness the moment when a final product is born. Of course I’m satisfied when I finish making a mold myself, but it’s only when the resin is poured into the mold and the parts produced without problems are assembled into a final product that the mold can truly be said to fulfill its role. No matter how many molds I make, I always find this both fulfilling and fascinating.”properties and molding conditions. You have to take these factors into consideration when designing and manufacturing molds.”As mentioned above, precision is obviously the key aspect of mold design. But cost matters, too. To produce a part having a cer-tain shape, should the mold consist of two pieces to be combined, or three, or four? This process is called mold layout, and because it reflects the approach and style of the individual in charge, it differs for each person. While using fewer pieces may seem more cost-effective, in some cases, using four pieces can reduce costs compared to using three. Mold layout isn’t always a straightfor-ward process.“For example,” explains Ozawa, “when Murata designs a mold, the other two would never accept it as is, suggesting some mod-ification or other from each point of view. This is the same for whomever among us happens to be in charge of design.”Murata says it’s hard to say how many years of experience it takes to become a skilled mold craftsman. In the past, the mold-making industry was supported by many craftsmen who had spent decades in the field. But today, what matters most isn’t the quality or range of an individual’s skills—it’s how the entire 9
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