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• Research and development efforts

Research and development system and component technologies that realize the unlimited possibilities of plastics

At Starlite, along with "seed-oriented" research and development to discover new possibilities for plastics, we also conduct "need-oriented" technology development based on close cooperation with users. The possibilities inherent in plastic are so great that we cannot even imagine them all. In order to make use of the fruits of science and technology for the benefit of humanity and nature, as we apply our accumulated expertise and technology and maximize our abilities to create new technologies, we are seeking to make Starlite an enterprise that is both a source of technology and a trusted business partner.

Tribology

The word "tribology" was created in 1966 in the UK and means "the study of friction, wear and lubrication." We consider this academic field, which specializes in research on friction and related material effects, to be one of Starlite�s core technological strengths. Depending on the form, friction can be categorized as sliding friction or rolling friction, and wear can be categorized as being caused by adhesion, abrasion, fatigue or corrosion, for example. What form the friction wear takes and how those characteristics change according to the load, speed conditions and lubrication methods must be determined according to the purpose of a product, and selecting and developing materials suitable to these conditions is necessary. At Starlite, based on this foundation of tribological research and application research, we are working to develop low-friction members and braking members that overcome the limits of conventional plastics.

Material development and fabrication technologies

For parts that are used in products, various special material characteristics are needed according to their applications, environments and other conditions. At Starlite, we do not just mold the materials produced by raw material manufacturers as is. In order to be able to develop original materials according to the diverse needs of our clients and respond to their various purposes and applications, we have brought together synthetic reaction equipment, various types of combining and mixing apparatuses, kneading extruders, material conveyance devices and other equipment.

Evaluation technologies

Materials development and evaluation technologies are two sides of the same coin. To achieve the desired material characteristics, the technology and equipment to evaluate them accurately are indispensable. At Starlite, we have developed our own tribological evaluation equipment, including apparatus for journal bearing testing, thrust bearing testing, pin-on-disc testing and gear testing. In addition, we have also arranged various types of measurement devices necessary to accurately record and analyze the results of tests. With this comprehensive assembly of equipment at Starlite, we implement short cycles for the investigation of hypotheses and the evaluation of prototypes to reliably produce the best finished materials. Furthermore, we also have various types of analytical devices, including an FT-IR and an X-ray fluorescence spectrometer, and we are conducting thorough management of material quality.

Mold technologies

The investigation of numerous design factors is necessary in the design and manufacture of plastic products and their molds. Product shape and thickness, the number and location of gates, resin selection, contraction rate setting, mold structure and all the other key factors have mutual interrelationships. These factors are simulated using CAE to anticipate resin flow, mold cooling, product shrinkage, warp and distortion, structural problems and other issues so that at the design stage, product and mold designs and molding conditions can be made most suitable and the best results can be achieved with the least cost. At Starlite, by using analytical software such as TIMON and ANSYS, we greatly reduce the amount of effort spent in conventional trial and error methods, and minimize the time required to reach the mass production stage. In addition, we utilize Pro-Engineer, I-DEAS and other 3D CAD software and cooperate in the design and development of client products. In addition, we also reduce lead-time by applying these efforts to the manufacture of molds after accepting orders.

Molding and secondary processing technologies

Even in the plastic molding processing industry, Starlite is one of few businesses that handles both thermosetting and thermoplastic materials. Our molding equipment and technologies are extensive and diverse enough to handle both, and we can undertake the molding of every type of plastic. For thermosetting plastic, this includes compression molding, roller molding, continuous laminated molding, casting and injection molding, while for thermoplastics, this includes injection molding, precision injection molding, injection compression molding, co-injection molding and large-scale low-foam molding. Moreover, we also conduct compression molding, injection molding, extrusion molding, transfer molding and Poisson molding for fluorine resin. We determine the molding conditions for the materials that we develop to maximize the manifestation of their special characteristics, and we make products that combine our three areas of technological expertise in materials, molds and molding. Moreover, we also develop automation equipment for individual products, among other efforts to rationalize secondary processing and stabilize quality.