Innovative Technology with Iepco Surface Treatment! Benefits of Reduced Demolding Resistance

Within the manufacturing industry, “mold release” – the smooth removal of products from molds – is a critical challenge for enhancing productivity and quality. Sanko Gosei Co., Ltd. has introduced the Swiss-origin Iepco surface treatment technology, significantly reducing mold release resistance to achieve efficient, high-quality production. This article provides a detailed explanation of Iepco treatment fundamentals, specific application examples for reducing mold release resistance, and its effects.

What is Iepco Surface Treatment?

Iepco surface treatment is a technology that densifies the surface of metal components, enhancing performance and extending service life. Developed by Swiss aviation engineers to prevent turbine blade fractures, it is now used across diverse fields including aircraft components, automotive parts, and medical devices.

Characteristics

Fills microscopic cracks and pits, smoothing the surface.

Removes work-hardened layers, burrs, and flash.

Improves surface smoothness, enhancing sliding properties and release characteristics.

Sanko Gosei introduced Iepco processing equipment in 2014, focusing its application particularly on improving mold release properties.

Iepco Surface Treatment Process

Iepco surface treatment is carried out through the following steps:

Masking and Cleaning

Masking of areas not requiring treatment, followed by removal of dirt and grease.

Cleaning Process

Removal of work-hardened layers and burrs, preparing a clean surface.

Peening Process

Fills minute defects using specialised powder, densifying the surface.

Prior to applying the Iepco treatment, the product adhered to the mold, making it impossible to remove. However, after treatment, smooth demolding became possible, significantly improving productivity.

Before treatment: Product adhered to the mold, making removal difficult.

After treatment: Product demolded easily, improving work efficiency.

2. Example of a Tapered Block

Difficulties in removal had been occurring at the inclined sections within the mold, but the Iepco treatment improved demolding properties, resolving the issue.

Effect: Reduced mold maintenance frequency due to improved demolding properties.

3. Application to other molds, including test molds

Treatment has been implemented on over 20 molds to date. Particularly significant effects have been achieved with products utilising elastomer resins.

Effects of Reduced Demolding Resistance

Enhanced Productivity

Smoother product release shortens molding cycle times, increasing production capacity.

Extended Mold Lifespan

Reduced demolding resistance minimises mold wear, lowering maintenance frequency.

Stabilised Quality

Improved product surface finish reduces defect rates.

Cost Reduction

Comprehensive cost performance improves through reduced maintenance and fewer defective products.

Future Challenges and Outlook

Challenges

Expanding Applicability Range

Current equipment is limited to mold sizes of 700mm × 700mm, making compatibility with large molds a challenge.

➡Introduction of large-scale Iepco equipment now enables maximum workpiece dimensions of 2,300mm x 1,400mm and weights up to 5 tonnes! Details here 👉Large-scale Iepco Equipment Production

Processing Condition Optimisation

Further investigation is required into variations in effectiveness due to initial surface conditions, such as surface roughness and undercuts.

Outlook

We are considering developing our own large-scale equipment to apply the treatment to a wider range of molds.

We aim to expand our contract processing services in the market, meeting the surface treatment needs for mold components and end mills.

Summary

Iepco surface treatment is an innovative technology that dramatically improves mold release properties. In the case of Sanko Gosei, production efficiency and quality improved substantially due to reduced mold release resistance. Particularly notable effects were achieved with elastomer resin products, and further utilisation is anticipated.

For manufacturing sites facing challenges with mold release, Iepco Surface Treatment offers a powerful solution. Those considering introducing the technology are encouraged to consult with specialists.