A Common Basic Technology: Die/Mold Technology

1. A Common Basic Technology:Die/Mold Technology Dr. Weng-Sing Hwang President Metal Industries Research and Development Centre August 4, 2006

2. Contents 1. Why Die/Mold is a Common Technology 2. Why Die/Mold is an Important Basic Technology 3. Current Status of Taiwanese Die/Mold Technology 4. Strategies for A+ Die/Mold Technology 5. Conclusions

3. 1. Why Die/Mold is a Common Technology 1 What is a Die/Mold (1). Forming methods for components/parts: Machining: Extra material is removed by tools, including turning, milling and grinding. Die/Mold Manufacturing: Material is shaped through constraining or extruding die/mold. Die/Mold is the prerequisite for mass production. a. Molds: Material is formed during molten state, such as plastics injection molding and casting mold; b. Dies : Material is formed during solid state, such as stamping, forging and extrusion. Rotate sand wheel Rotate workpiece Rotate milling cutter Feed Feed workpiece Feed workpiece Move tool

4. Basic Structure of Bending Stamping Die-V Type Workpiece (before forming) shank Upper die punch guide plate Lower die Die Die set Workpiece (after forming)

5. Plastics Injection Molding Process Step 1: plasticization Step 2: Injection Step 3: Ejection

6. Die/Mold-- Foundation of Industrial Products ＊Die/Mold are the key tools to make components & parts. They are also called the mother of industrial products. Through mold & die, the components & parts are able to be made in low cost, mass production and uniform quality. ＊Though total production value of mold & die is not very high, each set of mold can create the production value at 10~50 times. Production value derived from mold & die in Taiwan area is estimated to exceed NT$1.8 trillion.

7. Market for Products Manufactured through Die/Mold in 2005

8. Demand of Die/Mold for Auto Parts Aluminum frame structure Adhesive bonding of Structure • Each automobile requires 1700 sets of stamping die, 500 sets of plastic injection mold and 1000 sets of casting mold. • Expense of mold & die is about NT$3~5 billion. Aluminum casting parts Wear-resistant transmission parts Rocker arm/bearing Magnesium casting parts

9. Demand of Die/Mold for Notebook Components Casing, frame (Aluminum, magnesium, die casting, sheet hydroforming) IO terminal (stainless steel→titanium) (precision stamping) HDD Parts、 CD Yoke （Press forging） Plastic casing (Injection mold) Every Notebook requires about 50 sets of mold & die for mechanical and casting parts.(Excluding purchased parts, such as flat panel, hard disc, thermal module) 30um fine line (Micro welding, hydro static extrusion) Heat pipe with 0.5mm thickness Battery can (Deep drawing) CPU, IC Thermal module (Counter pressure, press forging) Thickness precision<±0.015mm

10. 2. Why Die/Mold is an Important Basic Technology

11. Precision of Die/Mold Affects Product Precision

12. Connector Parts Manufactured through Die/Mold Global production value of connector: US$36.429 billion Production value of connector in Taiwan: US$3.125 billion Import value from Japan in 2004 US$0.31 billion ●Game machine（such as Sony’s PS2、Microsoft Xbox） ●MP3(iPod) ●Computer (Desktop, NB） ●Cell phone ●Digital camera ●PDA ●Printer ●PCMCI PC Card Kit ●Optical connector ●Automobile ●LCD TV Classification of Connector 1.Rectangular(A) 2.Circular(A) 3.Memory card(A) 4.Board-to-Board(A) 5.FPC/FFC(A) 6.Coxial(B) 7.RF Coxia(B)l 8.Module(A) 9.Card Edge(A) 10.Antenna(B) 11.LAN(B) 12.ECU(B) 13.HID Lamp(B) 14.Board-to-Wire(A) 15.Optical(C) PS：A-Domestic technologies are matured B-Part of domestic technologies is matured C-Rely on importation Applied Products Technical bottleneck • Forming parameters • Machining precision of mold & die • Tolerance control of die/mold parts • Assembly tolerance of die/mold

13. Extrusion of battery can requires ten stages of die process and each stage can not tolerate any defect. Technical Difficulties Too small Too large Too large Too small Too small Material holding pressure Die clearance Punch R Too large Wrinkles on flange drawing Breakage on punch radius Die center misalignment Typical example of NG extrusion parts Breakage on side wall

14. Surface Treatment and Heat Treatment for Die/Mold Proper heat treatment/surface treatment can prolong die/mold life. It then improve productivity and hence competitiveness. IC packaging die Previous method: Hard Cr electroplating R&D result:Cr-flon treatment Benefit: Previous method had to clean mold for 2 hours after 500 shots. New coating upgrades to clean mold for 1 hour after 800 shots and increases die life for more than 50%. Nitriding hot forging die for crank shaft of motorcycle/ion increases service life by 3-4 times

15. A+ Die/Mold Technology must Combine Theory and Practice Progressive die for precision terminal (280 pieces components)Component precision: 1-3μmPrecision after mold & die assembly: 8μm ＊Die/Mold technology is an integral technology. It includes material flow, control theory, precision processing, heat treatment, surface treatment, structure/mechanism, heat dissipation and tribology as well as knowledge in forming machine. ＊Excellence in individual technology can not produce a good die/mold. It must take integral thinking, take care of every single element and facilitate good coordination among elements to complete a good mold & die. Therefore the ultimacy of mold & die technology is often considered more of an art than a technology.

16. 3. Current Status of Taiwanese Die/Mold Industry Die/Mold Structure Ejection pin (Ⅱ) Ejection pin Ejection plate Ejection pin (Ⅰ) Die set QFP-48 Press Die Punch back plate Punch plate Punch plate Ejection block Upper die plate Guide pin Stripper die plate spring Stripper bolt Die plate Die insert

17. Contents of Generic Technology for Die/Mold Manufacturing Process Material Inspection/ Certification Design Process design & simulation Mold & die material specification Mold & die structure/ mechanism Mold & die stiffness/ strength Product material forming property Mold & die surface treatment Mold & die heat treatment Mold & die machining Design & selection of surface treatment Design and selection of heat treatment Material selection Measurement method Design and selection of jig & fixture Surface polishing Machining process Tools selection Jigs & fixture selection

18. Comparison of Manufacturing Level for Domestic & Foreign Mold & Die Manufacturing precision Price competition After-sale service Product life Inspection ability Design capability Production speed Taiwan Taiwan USA Japan Germany South Korea South Korea Mainland China others Singapore Source: Taiwan Mold & Die Industry Association; MIRDC’s ITIS project

19. Taiwan still relies on import for precision die/mold Industry must enhance basic technology to set up the key technologies of ultra precision mold & die DVD, optical, precision elements of MEMS dimensional precision ±1μm (every mold) dimensional precision ±1μm (mold) Imported components & parts exceeded NT$200 billion in 2003 (Ex.): Production value of TFT-LCD 尺寸精度±1μm (每m) 特徵精度0.1m 2002 (actual): NT$ 3500 billion (V) 超精 密級 Characteristic precision 0.1μm (Technical bottleneck of Taiwanese mold & die industry) Characteristic precision 0.1μm Ultra precision level 2006(target):NT$ 1 trillion 370 billion (10家) (Tech) 尺寸精度±3μm(每m) 2002(actual):NT$1 trillion dimensional precision ±3μm (everymold) （汽車零件、3C精密 薄殼產品….） (IV) Precision level Auto parts, 3C precision thin-wall products 2006(estimate): NT$ 1 trillion 100 manufacturers Casing of home appliances, stationery （一般家電外殼、文具….） (III)Secondary precision level （日用品、家具….） Daily goods, furniture (II)General level Agriculture, industrial usage （農、工業用途….） (I)Cheap level Total Number of Taiwan Mold & Die Manufacturers: 3,526

20. Current Status of Taiwanese Die/Mold Industry ＊Production value of Taiwanese die/mold industry amounted NT$50 billion in 2003, roughly accounting for 4.3% of total global production value. The production value ranked the 8th place in 2003. However, it took the 6th place in 2002. Additionally the ranking of production value came behind Japan, USA, Mainland China, Germany, Italy, France and South Korea. ＊Main competitive advantages of Taiwanese die/mold industry include quick production speed and excellent quality. Taiwan is second to Japan in Asia. The complete and flexible production system of Taiwanese mold & die industry is the target to be followed by other countries. In average, the price of Taiwanese mold & die is about 70% of that of Japan, while Mainland China is about 70% of Taiwan and South Korea is about 90% of Taiwan. ＊The import unit price of Taiwanese die/mold is 2~3 times of export unit price, indicating the technical level is required to be upgraded. ＊Taiwan has 3,500 mold & die manufacturers. In terms of technical level, less than 10 manufacturers can be classified as ultra-precision level (with size precision ±1μm), under 100 manufacturers can be listed as precision level (with size precision ±3μm). Regular mold & die facing the competition from Mainland China, Korea and South East Asia, its capabilities require to upgrade. ＊As product requires higher and higher precision, the domestic mold & die technology is not sufficient to meet the requirements so that the imported components & parts exceed NT$200 billion per year.

21. Problems Faced by Domestic Mold & Die Industry ＊The average number of employee for domestic mold & die industry is 12 persons. It relies on passing experience. It has weak theoretical base and insufficient R&D capabilities. ＊Transformation of Taiwanese product manufacturer is focused on R&D. In the development stage, die/mold is developed in Taiwan and is relocated to low cost area in mass production stage. Die/Mold manufacturer must enhance innovative R&D capabilities, basic technology, and talented people (Otherwise 40% of manufacturers, about 1,400 makers, is estimated to withdraw from market). ＊Some system manufacturers sets up its own die/mold shop as domestic die/mold makers are not equipped with the development capabilities. However, they also face the same problems, including the upgrading of basic technology, knowledge and talents. ＊ The capability in basic research to facilitate the development of die/mold technology becomes weaker and weaker in educational and research systems. The number of department, professor and graduate student to be dedicated to study of Ph. D and master thesis as well as B.S. program are gradually decreased.

22. Problems Faced by Domestic Die/Mold Industry—Can’t do or Won’t do ＊Ultra precision die/mold (dimensional precision ±1μm, V level) must be comprehensively upgraded from material, equipment, manufacturing process and inspection. →Domestic die/mold industry has the difficulty to establish R&D by itself. →MIRDC takes the leading role to invest and work with other academic & research institutes for joint R&D. ＊The basic technical data for precision die/mold (precision ±3μm, IV level) are not sufficient so the development time is too long and the cost cannot be controlled. ＊The establishment of basic technology, sponsored by government, will prevalently increase the assurance for development, shorten the development schedule, increase the development willingness and further facilitate the overall industrial upgrading.

23. 4. Strategies for A+ Die/Mold Technology Develop the basic common technology for A+ die/mold to upgrade the domestic die/mold industry. Definition of A+ die/mold: ● Precision requirements: -- Precision level (IV level): ≦± 3μ m -- Ultra-precision (V level): ≦±1μ m ● Long life span ● High product yield rate: easy for use and maintenance • High product complexity: 3D profile or compound machining • Short delivery: delivery accuracy 95%

24. Development Strategy of Die/Mold Technology Micro Die/Mold Project Break through technical bottleneck Provide common lab. and assist the development Common/Basic Technology Research Optical, MEMS V ultra precision level Dimensional precision under 1 μm 10 makers VI ultra precision level Dimensional preciison under 3μm Collaborative Development Platform Auto, 3C 100 makers Knowledge database Manpower cultivation Ⅲ secondary precision level Provide JDM environment Bring about rapid upgrading of overall capabilities Dimensional precision 3~10μm 200 makers Home Appliance Ⅱgeneral level 10~20μm Case Consultation 3000 makers Daily Goods I cheap level Total 3,500 makers

25. Development Strategy of Common/Basic Die/Mold Technology for A+ Die/Mold

26. Strategy of Establishing Common/Basic Technology for Precision Die/Mold MIRDC: － Collect & compile technical information and identify the insufficiency － Study of localized technologies － Demonstration and promotion 1. Responsible for collection and analysis of the related basic technologies 2. Technical certification 3. Study of localized basic technologies 4. Set up promotion mechanism and network 5. Promotion and service providing 6. Integrate domestic academic & research resources, provide the services and assist the industry to upgrade 7. Set up, maintain and update the knowledge database website 8. Introduce foreign advanced technologies and facilitate them to be localized ※15-20% of annual budget is used to conduct the industrial & academic cooperation and international cooperation

27. Strategy of Establishing Common/Basic Technology for Precision Die/Mold (Cont.) Academic sector: Set up localized knowledge and conduct manpower cultivation 1. Analysis and comparison of domestic & foreign mold & die machining and the related forming theoretical models 2. Practicability analysis and comparison for localization 3. R&D of applicable theoretical models for localization 4. Conduct long-term cooperation with non-profit organizations, set up focus research capabilities and become long-term R&D and service partner Stamping die, forging die, material and heat treatment have been identified with specific manufacturers to discuss the details. The cooperative targets of injection mold, die casting mold, machining, inspection and knowledge database are still under discussion.

28. Strategy of Establishing Common/Basic Technology for Precision Die/Mold (Cont.) Industrial sector: Provide technical information and verification services 1. Participate R&D led by institution with target on suppliers and equipment makers, such as machine tool maker, tooling factory, heat treatment plant, material manufacturer and software company. 2. Manufacturers actively provide their related technical information or corporation technology development program formulates the topics to locate the manufacturers to conduct the cooperative research. 3. Research results are included in knowledge database for public sharing. 4. If the industry, actually develops mold & die, is willing to share the results publicly, then joins the R&D of institution, otherwise conducts the related technical development through industrial technology development program.

29. Cooperation of Industry, Academic and Research Sectors for Ultra Precision Level Die/Mold Equipment makers System Makers Other Institutions • 設備開發建置 MIRDC Design Co. （Design Dept.） Academic Institutions Through specific cases, MIRDC cooperate with product company, die/mold makers, equipment makers and other academic & research institutions to conduct systematic development. • Market analysis, forecast and specifications setup for new products with development potentiality • Manufacturing technology R&D • Planning of manufacturing & assembly production line • Prototype and small batch production • Cultivation of manufacturing/mold & die technical talents • Establishment of product specifications • Design of prototype product • System simulation and analysis • Development and setup of equipment • Development and setup of equipment • Complimentary technical research • Basic research • Theory and simulation analysis • Setup of experimental equipment • Database establishment • Mass production and assembly • Technical evaluation and suggestion • Guide of manufacturing technology design • Prototype test

30. Benefits to the Industry Industry Knowledge database of common basic technology for die/mold Shorten Development time 25-75% Knowledge database of specific products Save setup cost NT$20-50 million Shorten manpower cultivation time 10 years → 5 years Education/training material for manpower cultivation Increase confidence of developing new product Save trial times to 2 times Trial & Error → Theory & Prediction

31. 5. Conclusions ＊Die/Mold technology tremendously affects the economic development in the nation. It is the industry that is greatly supported for development by the advanced countries as well as developing countries. It is the industry to be developed in Taiwan. Target: unit price of die/mold reaches 85% of that of Japan in 2010. ＊Die/Mold industry in Taiwan needs more theoretical bases and talents, which will enable the upgrading to precision level die/mold. Previous research did not offer too much assistance in the upgrading of overall industrial technology and the development of national competitiveness due to limited budget and talents. ＊The research of basic technology for from A to A+ mold/die, supported by government and compilation of knowledge-base and database will not only benefit die/mold makers, but also offer tremendous assistance to the industry which is to be transformed into design-oriented industry. ＊This project has gained excellent response. Currently MIRDC has conducted the research planning with some industry, academic and research institutions. In the future, the concerted effort will facilitate sound and smooth implementation of this project.

32. 5. Conclusions (cont.) ＊Common/basic technology for precision level die/mold is to collect & compile the domestic & foreign information and conduct R&D to modify and localize information. They can be used in manpower cultivation and in knowledge-base for collaborative development platform to speed up the development time. ＊Ultra precision level mold & die is the key for future product development.The comprehensive development of material, machining, manufacturing process, inspection and equipment is a key to the production of ultra precision die/mold.The development of ultra precision die/mold must have the concerted effort of industry, academic and research sectors. First specific vehicle product is to be developed. Then the whole industry is thus promoted and developed.

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34. Contents of Generic Technology

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37. Contents of Generic Technology

38. Mold & Die Industry Development Projects in Asian Countries 1.Common Ground of Mold & Die Industry Development Projects in Japan and Korea －Enhance export competitiveness－mold & die industry supports the product development －Government sponsors the research of future competitive ability: micro-fabrication, precision upgrading and intelligent －Application of IT－shorten delivery and reduce cost －Upgrade development capabilities of new technology and new product: new material forming and mold & die design & machining, new product development －Cultivation of high class design talents 2. Mainland China －Mold & die industry is continuously listed as national important industry －Increase import tariff of mold & die tremendously 3. Singapore －Allocate S$2 million to conduct the planning of TDM (PDM of mold & die industry) system －Allocate S$3 million to conduct the cultivation planning of mold & die design & manufacturing engineers and invest S$500 million to set up precision machinery and mold & die cultivation system 4. Thailand －With Singapore’s assistance, Premier directly supervises to develop the auto and its components & parts －Allocate THB$60 million to conduct the cultivation planning of mold & die talents and estimate to invest THB$1.69 billion to cultivate 7,000 persons within 5 years

39. 超微細、超複雜、高耐久、超高速用模具開發 • 新興材料對應模具開發 • 高速省能源型機械開發 • 複合特殊技術開發 • 技術力強化 • 短交期化/成本削減 • 海外市場開拓 Source: Die and Mold Technology (Nov. 2004)/compiled by MIRDC’s ITIS project General Status of Mold & Die Development in Japan Strength of Japanese mold & die industry • Development of mold & die for ultra-fine, ultra-complicated, durable and high speed purpose • New emerging materials response to development of mold & die • Development of high speed & energy saving type machine • Development of hybrid special technology Target of industry development Enhance technical capability Short delivery/cost reduction Explore foreign market • Application of IT • Increase the design completeness of high class products

40. Development Project of Mold & Die Technology in Japan • Estimated amount: Japanese Yen 4 billion • Duration: 2003~2005(three years) Application of automobile & industry machinery 汽車及產業機械應用 Thixomolding technology for high fusion point metal Casting die of high functional material Forging die of high functional material Mold & die forming technology for new materials Forming technology of flexible molds for poor machinability light metal Plastic injection mold of new material Development of exhaust part for high precision injection mold RP/RT hybrid mold manufacturing technology For example: mobile phone battery housing/ SD memory card Main targets of development for mold & die machining technologies 如︰手機電池殼/SD記憶卡 Micro free curve & complicated shape, including aspherical lens/ micro remote device/hologram optical element Required high precision/high speed transfer technology of DNA analytical instrument and high density LSI DNA分析儀器及高密度LSI等所需高精密/高速大量轉寫技術 Ultra micro forming mold Nano size mold & die forming technology Ultra-precision/3 Dimension Ultra precision plastic injection mold Asymmetrical aspherical shape optical parts Forming technology of complicated shape mold & die High precision stamping die Ultra-precision machining/measurement technology Utilize ultrasonic micro/nano mold & die forming technology • High precision blanking of LSI lead frame • High precision extrusion of motor housing for CD ROM • High precision groove machining of fluid dynamic bearing for Hard Disk Drive(HDD) Source: Die and Mold Technology (Nov. 2004)/compiled by MIRDC’s ITIS project

41. Mold & Die Technology Development Projectin Korea Source: Ministry of Commerce, Industry and Energy/compiled by MIRDC’s ITIS project

42. Development Target and Strategy of Mold & Die Industry in Taiwan Production value of precision level mold & die makers doubles NT$100 million Future(2008) IV & V class integration mold & die, focus on mold & die of the development stage, number of mold & die makers for precision level doubles Total production value Strategic Measures Implement industry’s type with focus on joint design & manufacturing (JDM) 800 Major Focuses －Construction of collaborative design development environment －Cultivation of design engineers － Assistance of IV level technical upgrading － R&D and promotion of V level technology Current status (2004) Traditional mold & die technology of Ⅲ &IV class, focus on mold & die for OME product, about 100 mold & die makers for precision level 566 Year 2004 2008

43. Analysis of Generic Technical Ability for Domestic IV Level Mold & Die

44. Import Information of Import Components & Parts Import Value in 2004 Unit: NT$100 million

45. Connector Applied Industries of Components & Parts by Mold & Die Global production value of connector: US$36.429 billion Production value of connector in Taiwan: US$3.125 billion Technical bottleneck -Forming parameters control of mold & die -Machining precision control of mold & die -Assembly tolerance control of mold & die -Tolerance control of mold & die parts Connector’s classification 1.Rectangular(A) 2.Circular(A) 3.Memory card(A) 4.Board-to-Board(A) 5.FPC/FFC(A) 6.Coxial(B) 7.RF Coxia(B)l 8.Module(A) 9.Card Edge(A) 10.Antenna(B) 11.LAN(B) 12.ECU(B) 13.HID Lamp(B) 14.Board-to-Wire(A) 15.Optical(C) 註：A-Domestic technologies are matured B-Part of domestic technologies is matured C-Rely on importation

46. Analysis of Basic Research for Generic Mold & Die Technology Fish Bone Chart of Application for Deep Drawing Die Technology Design and analysis of mold & die Assembly and measurement of mold & die Mold & die machining & manufacturing Assembly platform Size measurement CAD technology Material property EDM Machining Radius contour measurement CAE analysis Assembly tools Design database Grinding WEDM Strip layout Process design CAM technology Polishing Measurement of surface coarseness Deep Drawing Die Technology Quick die change Transfer press Vacuum heat treatment Ion nitriding Safety device Sensing technology CVD PVD Transfer fingers Feeder Surface coating technology TRJ Lubricant selection Heat treatment and surface treatment of mold & die Trial and finished products

47. Main Development of Mold & Die Technology at MIRDC (S & T Project) Development of micro-fabrication system World leading institution Development of production system for value-added heightening products World class institution •Fine wire∮<17μm L>300m/min •Aspect ratio L/D > 8 •Optical pick-up head •4mm prismatic batter can • Long copper probe Domestic leading institution R&D of system integration technology Domestic first class institution •Strip cold forging progressive die •Deep drawing die for sheet metal Kc 〉60 •High speed drawing transfer die spm 〉200 •casting rapid die with wrought like material Increase industry competitiveness •Upgrade mold & die technology •unit price of precision stamping die increases 4 times •Die casting mold enters into security parts market •Forging die enters into S4 level market •Prolong mold & die life and increase production value more than NT$5 billion •Localized process and integration of mold & die technology replace import machine •Upgrade mold & die technology •unit price of precision stamping die increases 4 times •Die casting mold enters into security parts market •Forging die enters into S4 level market •Prolong mold & die life and increase production value more than NT$5 billion •Localized process and integration of mold & die technology replace import machine Construct development infrastructure of mold & die •Development of localized software to increase the efficiency of 40% •Promote mold & die design manual more than 3,000 volumes •cultivation of mold & die talents accounts for more than 25% of mold & die design talents Innovative mold & die technology Industrial application oriented Establish mold & die technology for generic demand Establish mold & die technology for generic demand 2000 2001 2002 2003 2004 1998 1994 1995 1996 1997 1999

48. Cheng Kung Univ.-Motor －Analysis & Research of Thinning Design for Penny Motor Yunlin Univ.-Micro EDM • －R&D of equipment & manufacturing process for micro EDM Chung Hsing Univ.-Mirror Machining • －Use mirror machining system at Chung Hsing to jointly develop product and conduct industrial service Kaohsiung First Univ.-Mold & Die － MIM Research • －Technical consulting center of mold & die design & manufacturing process Kaohsiung Univ. of Applied Science-Optical mold & die • －Micro plastic injection mold technology • －Design and inspection of backlight module －Cultivation of mold & die talents Established Strategic Alliance with Academic & Research Sectors MIRDC

49. Origin Co. in Japan －Analysis & Control technology of micro resistance sealing welding process LFT in Germany －R&D of Metals Formability in the application of micro/meso manufacturing Daido Machinery in Japan • －R&D of micro forging process • －Design & Development of mini-cassette change former LEM in Japan • －Design & Development of Micro-press NIU in America • －R&D of micro-forging process • －Design & Development of Micro-forging die GIT in America • －Research & application of Spatial error compensation technology Others (under negotiation) • －Japan AIST/Korea KIMM, etc. • －Micro-manufacturing related system technologies Zyvex Co. in America • －Micro-Assembly Statistics Technology International Cooperation Material MIRDC Equipment Manufacturing Process Assembly

50. Project Contents Explanation