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

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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

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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 workpiece Move tool Feed Rotate milling cutter Feed workpiece Rotate sand wheel

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

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

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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.

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7 Market CategoryExamples of Applied ProductsCalculation Basis Production Value (NT$100 million) Civil industryFurniture, toys, sports goodsSpecific products1,000 Chemical industry Plastic & rubber productsSpecific products3,410 Home appliance Refrigerator, washing machine, electric fan, table lamp. Specific products, Ratio of product by mold & die is 50% 275 Information electronics 3C components, opto-electronic components 1. Specific products, Ratio of product by mold & die is 50% 2. Deduct repeated calculation 6,594 Fabricated metal product Hand tools, fasteners, forging, stamping parts Specific products2,750 MachineryVarious machine parts 1. Specific products, Ratio of product by mold & die is 70% 2. Deduct repeated calculation 2,380 TransportationAuto parts, motorcycle parts 1. Specific products, Ratio of product by mold & die is 70% 1,900 Power equipmentBattery, switch elementSpecific products225 Total18,534 Market for Products Manufactured through Die/Mold in 2005

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8 Wear-resistant transmission parts Rocker arm/bearing Aluminum frame structure Magnesium casting parts Aluminum casting parts 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. Demand of Die/Mold for Auto Parts

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9 CPU, IC Thermal module (Counter pressure, press forging) Plastic casing (Injection mold) 30um fine line (Micro welding, hydro static extrusion) Battery can (Deep drawing) Casing, frame (Aluminum, magnesium, die casting, sheet hydroforming) Heat pipe with 0.5mm thickness HDD Parts CD Yoke Press forging IO terminal (stainless steeltitanium) (precision stamping) Thickness precision

47 Main Development of Mold & Die Technology at MIRDC (S & T Project) Establish mold & die technology for generic demand 1994 199519961997 1998 2000 1999 2001 Construct development infrastructure of mold & die Increase industry competitiveness R&D of system integration technology Development of production system for value-added heightening products 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 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 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 Fine wire 300m/min Aspect ratio L/D > 8 Optical pick-up head 4mm prismatic batter can Long copper probe 200220032004 Development of micro-fabrication system Domestic first class institution World leading institution Domestic leading institution World class institution Establish mold & die technology for generic demand 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 Industrial application oriented Innovative mold & die technology

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48 MIRDC 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 Kaohsiung First Univ.-Mold & Die MIM Research Technical consulting center of mold & die design & manufacturing process 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 Cheng Kung Univ.-Motor Analysis & Research of Thinning Design for Penny Motor

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49 International Cooperation MIRDC 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 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 LFT in Germany R&D of Metals Formability in the application of micro/meso manufacturing Origin Co. in Japan Analysis & Control technology of micro resistance sealing welding process Zyvex Co. in America Micro-Assembly Statistics Technology Others (under negotiation) Japan AIST/Korea KIMM, etc. Micro-manufacturing related system technologies Manufacturing Process Assembly Material Equipment

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50 Project Contents Explanation

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51 Project Target and Expected Benefit Unit price of mold & die reaches 85% of that of Japan in 2010. Enhance basic technology of precision level mold & die, speed up technical upgrading and increase the design & development speed & efficacy. Mold & die makers for precision level double to 200 makers in 2008 and 300 makers in 2010 respectively. Systematically set up the basic technology of ultra-precision level mold & die to establish international competitiveness for main stream market in the future. Mold & die makers for ultra- precision level increase to 500 makers in 2010. Number of member for generic knowledge database of mold & die exceeds 300 in 2010. Combine academic resources to set up 5 basic technology service centers for mold & die in Taiwan in providing the industry with convenient services. Project Target

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52 Compilation and Research Planning of Basic Mold &Die Technology Affecting variable analysis and theoretical formula Database of domestic & foreign key variables Related framework of basic technical system Research planning and sorting of localized technical information Planning of basic mold & die technology database To be equipped with functional framework of mold & die knowledge database and authorization framework to use mold & die knowledge platform To ve equipped with knowledge management process and searching function Demonstration and Promotion Set up stamping die demonstration cases Complete more than 2 symposiums and panel discussions Complete the planning of service spots for mold & die technology in northern, central and southern region Complete one case of cooperative research planning with foreign institution FY95(Framework setup)FY96(Long-term cultivation) Study of Basic Mold & die Design technology Setup of precision design reference data, design criterion, upgrading of simulation snalytical capabilities and upgrading of assembly precision for stamping die, injection mold, forging die, die casting mold and PIM mold Study of Basic Manufacturing & Inspection technologies for Mold & Die - Size precision, profile precision, polishing, residual stress and strain, measurement and control of assembly precision Basic Technology Study of Materials and treatment for Mold & die - Influence of material micro structure and micro element, selection specifications, life pgrading and assurance, deformation control and size control Demonstration and Promotion - Selection of demonstration cases and collection & setup of information, promotional activities of project and recruit & service of knowledge database members, promotion of island service center, promotion of international cooperation, promotion of cooperative research with industry, academic & research sectors Study of Basic Technology for Ultra0Precision Level Mold & Die Selection of R&D Vehicle, labor of division for R&D institutions, introduction of foreign cooperative institutions Generic Basic Technology of A + Mold & Die

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53 Estimated Benefit Facilitate the doubling of value-added for mold & die industry and the doubling of export unit price for mold & die in 2010 with production value exceeds NT$90 billion. Knowledge database of generic basic technology for precision level mold & die can assist the industry to speed up the upgrading, reduce R&D cost and shorten the development time of mold & die to 30% and increase the development speed and efficacy. The knowledge database can decrease total development cost of NT$2 billion for industry every year (20 xNT$1 million x 100 makers). Assist mold & die makers to transform and participate the collaborative design & development model of product manufacturer by over 100 makers/times. The value of developed product exceeds NT$10 billion.

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54 Comprehensively compile the basic technology capabilities of mold & die, provide R&D basis for domestic upgrading & transformation and reduce the setup cost of industry more than NT$0.1 billion. One setup case is to verify the effectiveness of basic technology knowledge database. Effectively upgrade the development efficiency of mold & die and reduce the cost of industry more than NT$0.1 billion. The knowledge database is obtained after compiling & analyzing the basic mold & die technology that can be served as reference to the SOP and training material of mold & die makers, product development & design database of each maker & product as well as upgrading & development of industrys technology. Through member system, common knowledge database of basic mold & die technology facilitates the participation and information acquisition of users. Additionally common knowledge database can decrease the setup time and cost and update at any time. Expected Benefit in 2006

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55 Working Contents and Index in 2006 Sub-ProjectOutput Technical Indicator/Product Specification/Quality Indicator/Service Indicator A. Compilation and Research Planning of Mold & Die Basic Technology 6 basic technology reports of mold & die Stamping die Injection mold Forging die Die casting mold Material and heat treatment of mold & die Machining & inspection of mold & die affecting variable analysis and theoretical formula Design criterion (Variable controlling method/system) Database of domestic & foreign key variables Conduct technical survey of more than 30 domestic manufacturers related framework of basic technical system comparison of domestic & foreign technical Level Research planning and sorting of localized technical information B. Planning of Basic Mold & Die Technology Database Planning of functional framework for Mold & die knowledge database To be equipped with functional framework of mold & die knowledge database and authorization framework to use mold & die knowledge platform To be equipped with knowledge management process and searching function C. Demonstration and Promotion Knowledge database use cases of stamping die industry Set up one stamping die demonstration case Complete more than 2 symposiums and panel discussions Complete the planning of service spots for mold & die technology in northern, central and southern regions Complete one case of cooperative research planning with foreign institution

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56 Framework and Targeted Work from 2007 to 2010 Name of Component Project Targeted Work Study of Basic Mold & Die design technology Setup of precision design reference data, design criterion, upgrading of simulation analytical capabilities and upgrading of assembly precision for stamping die, injection mold, forging die, die casting mold and PIM mold. Study of Basic Manufacturing & Inspection technologies for Mold & Die Size precision, profile precision, polishing, residual stress and strain, measurement and control of assembly precision Basic Technology Study of Materials and Treatment for Mold & Die Influence of material micro structure and micro element, selection specifications, life upgrading and assurance, deformation control and size control Demonstration and promotion Selection of demonstration cases and collection & setup of information, promotional activities of project and recruit & service of knowledge database members, promotion of island service center, promotion of international cooperation, promotion of cooperative research with industry, academic & research sectors Study of Basic Technology for Ultra-Precision Level Mold & Die Selection of R&D vehicle, labor of division for R&D institutions, introduction of foreign cooperative institutions

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57 Budget Working ItemsCurrentCapital Grand Total Subcontr act, etc (included) Person -year Original planning in 2006 54,0006,00060,00013,00020 Approved in 200634,0006,00040,0007,20013 Planning in 200776,0004,00080,00014,00030 Planning since 2008 (every year) 78,0002,00080,00014,00031 Subcontracting research includes the cooperation with industry and academic sectors under contract and international collaboration

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58 Labor of Division for Mold & Die Related Projects Science & Technology Project Main ContentsRepresentative Contents Key Project Design, manufacturing, assembly & testing to develop micro products (components & parts made by micro mold & die) 2005-2006 Penny Motor To-CAN micro dual-in-line 2008-2010 Customization FDB (Design, manufacturing, assembly and testing of micro channel pattern) Development of micro drive system Environment Construction Project Development of machining technology for micro mold & die Hybrid process module within micro metal mold & die Micro stamping die and manufacturing process technology 2005-2007 Micro EDM module Mold & die of micro bearing 2008-2010 High quality micro EDM module Micro laser machining module Hybrid manufacturing process including lamination, laser, cutting and magnetic process Micro blanking, bending and drawing process

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59 Labor of Division for Mold & Die Related Projects (Continued) Science & Technology Project Main ContentsRepresentative Contents Basic Technology Project Basic technology of precision level mold & die (design, manufacturing, material & inspection) Study of ultra precision level micro mold & die 2006 Compilation and setup of knowledge database/ integrated study planning of parameters 2007-2011 Generic Study of precision level machining, inspection, polishing, material, heat treatment and surface treatment Design technology of precision level mold & die: stamping, injection, die casting and forging Demonstration vehicles: mobile phone housing, digital camera casing, connector, lens and gear Development of ultra precision level micro mold & die technology: micro injection, micro mold & die material and treatment, micro cutting, micro grinding, polishing

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60 Labor of Division for Targeted Work of Each Institution Department of Industrial Technology Industrial Development Bureau MIRDCOther Academic & Research Institutes R&D of Ultra Precision Level Mold & Die Technology (V Level) Program of foundation and facilities for study of mold & die and forming technology Key program of micro products Study of generic technology to set up basic capabilities Industrial technology development program to support R&D of new product technology Leading program of ultra precision level products Setup of micro mold & die and metal micro forming common Lab. DFMA information for specific vehicles Study of generic technology for V level,old & die Setup of Taiwan Micro- Fabrication Consortium (TMFC) Micro injection technology Micro milling machine Micro turning & milling hybrid machining Study of material formability and simulation of formability analysis

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61 Labor of Division for Targeted Work of Each Institution (Continued) Department of Industrial Technology Industrial Development Bureau MIRDCOther Academic & Research Institutes Precision Level Mold & Die Makers Double (IV Level) Setup of database for generic technology research to provide the use of establishing knowledge database of collaborative development Industrial technology development program supports product makers to establish the collaborative development system for demonstration To assist the setup of collaborative development system, including the operation mechanism, management mechanism and technical upgrading with target of 20 systems and 100 makers within 3 years Study of generic technology for IV level mold & die, to set up collaborative development knowledge database Assistance of collaborative development system Planning of knowledge database framework Handbook setup Generic technology basic study Setup of knowledge database information Manp ower Cultiv ation Information setup by generic technology study provides the cultivation materials of mold & die talents and E-learning contents Cultivation of design engineers On-thejob training Industrial master program on mold & die Cultivation and teaching materials compilation of stamping die design engineers Assistance of professional training Framework, contents planning & setup of E- learning Cultivation and teaching materials compilation of plastic mold design engineers Framework and content setup of E- learning Accreditation of mold & die talents

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62 Benefit Examples Name of Vehicle Existing LevelForeign LevelTarget (2010) Housing of penny motor for 3C products Technical indicator: 1. Blanking: 20m 2. Forming roundness: 30m Unit price of mold & die: NT$0.8 million Technical indicator: 1. Blanking: 10m 2. Forming roundness: 20m Unit price of mold & die: NT$2.5 million Technical indicator: 1. Blanking: 7.5m 2. Forming roundness: 10m Unit price of mold & die: NT$1.5 million Connector for auto (material: brass) Technical indicator: (1)Blanking: 30m (2)Bending: 1.5 (3)Forming: 50m Unit price of mold & die: NT$0.8 million Technical indicator: (1)Blanking: 10m (2)Bending: 1 (3)Forming: 20m Unit price of mold & die: NT$2.5 million Technical indicator: (1)Blanking: 7.5m (2)Bending: 1 (3)Forming: 20m Unit price of mold & die: NT$1.5 million