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Toshiba Machine develops two-step injection molding system for optical lens components

News 06.06.2016

Toshiba Machine Co., Ltd. announces that it released a system for simultaneous molding, assembly, and testing of two optical lens components of different shapes by combining an injection molding machine, robot, tester, and other peripheral devices.

Before, injection molding had to be performed separately for each product, followed by the assembly and testing processes, but this system performs a single process from injection to testing for providing a high-quality optimum solution at low cost.

Enables molding of two different products
Normally, for lenses and lens rim components that require assembly using the same resin, die manufacturing and molding are performed separately for each component. In this system, cavities with different shapes are produced in one die, and two-step injection control and die gate control of the injection molding machine are combined to enable optimum molding for each component in the same cycle.

Lower costs
Molding of two products with different thicknesses and sizes is performed in a single cycle for enabling reduced die manufacturing costs, allowing fewer setup operations, and eliminating storage costs for lower costs.

Automated processes for reduced labor
Toshiba Machine articulated robots and SCARA robots can be combined to enable automation of the product take-out, assembly, and testing processes. Using these robots allows stable and accurate assembly and transfer for improved product quality and 24-hour continuous operation for higher productivity.

"The optical resin specifications and diverse molding control of the injection molding machine enable the system to support a wide range of injection products, including thick lenses, diffuser lenses, clearance lamps, and more,” Toshihiro Kasai, manager of the Injection Molding Machine Division said. “An articulated robot can be used for product take-out to prevent the entry of foreign objects from the top of the molding machine and enable production of optical components in a clean molding environment.” He added, “The key feature of this system is its ability to perform assembly operations of part reversal and positioning in limited space, which is typically difficult for cartesian coordinate robots."

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