Creating Molds for Critical Safety Components

Haiten Kogyo is recognized as the first company in Japan to manufacture drawing molds using ultra-hard alloys, which are challenging to machine due to their high hardness. Besides processing ultra-hard alloys, the company specializes in unique techniques that combine different metals by taking advantage of their varying thermal expansion rates, distinguishing them from their competitors.

Machining generally falls into two categories: mold processing, which shapes materials using molds, and cutting processing, where material is removed from a solid block. Cutting processes tend to generate waste, such as chips, making them less efficient. With the rising prices of metals, the demand for mold-based processing has surged significantly.

When I was shown the products made using the company’s molds, I was impressed by the variety of screws and nuts on display, available in various shapes and sizes. It’s noted that about 60% of these components are automotive parts. While we may not often consider the screws and nuts that go into the wheels and engines of our cars, they are critical components that can significantly affect safety. The prototypes for these highly precise and essential parts are produced right here in Sakai.

Advanced Technology for Precision Finishing at 1/100 mm

“Unlike manufacturing methods that involve heating and forging materials, our cold forging technique allows us to forge at room temperature. This process eliminates shrinkage due to heat, ensuring dimensional accuracy and enabling finer processing,” explains Mr.Tomoya Saeki, the third-generation president of the company.

The technology we have developed since our founding in 1950, shortly after World War II, represents a rich legacy of knowledge and experience honed by our skilled craftsmen over the years. Our tools and products embody a deep sense of history and tradition. Inside the factory, a variety of machines line the floors, including some high-end equipment valued at tens of millions of yen.

“To accurately meet our customers’ detailed requests, we are committed to using the latest equipment. At the same time, our strength lies in the exceptional polishing techniques of our talented artisans. Their expertise allows us to finish complex shapes to a precision of 1/100 mm and achieve a delicate mirror finish with a surface roughness of Ra 0.02–0.03 μm. The tools our craftsmen use are custom-made by them, crafted using molds they have designed themselves.”

Bringing Specialized Technology Closer: BtoC Product Development

Harnessing the advanced technology of Haiten Kogyo, we have recently launched the brand KON-KOU.

“The molds we create are primarily for businesses, which means they are BtoB products. These molds are not the final products themselves but serve as tools for manufacturing items like automotive parts. As a result, we often don’t see how our products are used or what they ultimately become, making it hard to appreciate the impact of our work. In this context, our long-standing dream of producing original BtoC products has been to take on clear manufacturing challenges. By sharing our products with the public, we believe our employees will take greater pride in their work.”

KON-KOU gets its name from the concept of “a mixture of good and bad,” reflecting the fusion of various metal processing techniques, materials, and cultural influences from both past and present into a single product.

“This incense holder, standing at less than 10 cm tall, showcases the unique technologies and expertise we have developed over the years. We carefully machine the material to achieve a diameter of just 1 mm and a length of 40 mm, followed by electrical discharge machining to create a precisely matching 1 mm hole. Our skilled mold craftsmen rely on their intuition to make adjustments at the micron level (1/1000 mm) to ensure a flawless finish. During the final polishing stage, they meticulously remove any minor scratches or burrs that may arise during processing, preserving the shape while achieving a mirror-like shine. We hope you appreciate the meticulous craftsmanship our artisans bring to each piece.”

Celebrating Sakai’s Charm Through Incense Culture Collaboration

KON-KOU proudly collaborates with Sakai’s rich incense culture in a unique initiative. Each incense holder comes with incense sticks crafted by local high school students, embodying a heartfelt message of passing down the traditional incense-making techniques that have flourished in Sakai to future generations. By infusing the incense with the fragrance of Japanese tea, this project also highlights the enchanting tea ceremony culture that Sen no Rikyū popularized in Sakai.

KON-KOU, a creation of Haiten Kogyo, captures the distinctive essence of the traditional skills and high craftsmanship developed in Sakai within a compact incense holder. We invite you to take it into your hands and experience the passion behind it.

edit/text Tomoyo Tsuchiya
photographer Yutaka Sato

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