|
Pursuing Possibilities in Manufacturing Through Technologies and Creativity Fostered Through Racing Car Development
Takashi Miyaki
Manager, Safety and Environment Department
Toray Carbon Magic Co., Ltd.
Maibara City, Shiga Prefecture
|
|
|
|
| Address |
： |
215-1 Miyoshi, Maibara City, Shiga Prefecture |
| Established |
： |
April 2013 |
| Businesses |
： |
Investigation, research and development into composite materials; investigation, planning, design, production, development, manufacture and sales of composite products |
| URL |
： |
https://www.carbonmagic.com |
|
This Mitutoyo Report covers Toray Carbon Magic Co., Ltd., a company involved in the development of carbon composite products using CFRP (Carbon Fiber Reinforced Plastic). We asked about quality assurance at this company that continues to produce creative, high-added-value products by fully exploiting the technologies they fostered through racing car development.
Striving to improve functions of various products and parts
|
Various products using carbon composites
|
Toray Carbon Magic Co., Ltd. is a manufacturer of products made from CFRP, known as “carbon composites.”
CFRP is made from carbon fibers and resin raw materials. It is known to be a “light and strong” material with a strength 10 times that of iron. In addition, by offering a high degree of freedom in design and allowing the creation of integral parts and hollow structures unique to carbon composites, CFRP has been rapidly attracting attention as a substitute material for metal products in recent years.
The predecessor to Carbon Magic was Dome Carbon Magic in the Dome racing car constructor group.
“The development of racing cars is a competition in performance between composite materials, including carbon composites. Our background is the commercialization technology that we cultivated over many years in that harsh environment.”
Carbon Magic’s business is explained by Takashi Miyaki, Manager of the Safety and Environment Department who was previously engaged in the development of racing car parts.
”Our comprehensive development system from product concept and design to prototyping and mass production that we forged through racing car development gives us an edge,” says Mr. Miyaki. Under this comprehensive development system, Carbon Magic actively undertakes research and development aimed at value creation by fully exploiting the characteristics of carbon composites for products and parts in various fields and by expanding the possibilities of existing products.
“We are now at a transition period in history where materials are shifting from metals to carbon composites, and the potential demand is immeasurable. In this situation, we aim to not only meet the needs of customers but also create greater added value. We believe that researching and developing products that people can be convinced to use even when cost is considered will further expand the range of applications of carbon composite products.” Mr. Miyaki says.
|
Yu Shono,
Quality Assurance Department
|
Sales & Public
Relations Department
Assistant Manager,
Aki Matsuyama
|
|
Products using carbon composites
|
There are several molding methods that can create part shapes from carbon composites. One of these is the “autoclave manufacturing method” that Carbon Magic adopts to fully exploit the design flexibility of carbon composites. The selection of the autoclave manufacturing method is very significant for proposing new added value while precisely responding to customers’ requests.
Carbon Magic’s product development began with racing cars and is now actively expanding into diversified areas including aircraft, automobiles, industrial machinery and medical equipment.
Coordinate measuring machines in full operation for quality assurance
|
|
|
|
Mitutoyo CNC coordinate
measuring machine in full operation
CRYSTA-Apex S
|
As many of their products demand the same high level of machining accuracy as metal materials, Carbon Magic has also established a comprehensive quality assurance system.
“Of all the products we handle, medical equipment parts demand particularly high levels of accuracy. As handheld instruments such as vernier calipers are inadequate for measuring the positions and diameters of holes for the installation of precision machinery, we measure these positions using a Mitutoyo CRYSTA Apex S122010 CNC coordinate measuring machine,” says Mr. Yu Shono of the Quality Assurance Department.
This model was introduced in 2014. Mr. Shono recounts the process as follows: “The 5-axis control permits shape measurements that were difficult with three axes, and programming was so simple that even beginners like us could do it easily.”
When the CRYSTA Apex S 122010 became fully operational as business expanded, a CRYSTA Apex S 9108 was introduced in 2017 . Two CRYSTA Apex S are currently being used for the quality control of many products.
Mr. Shono has been involved with the quality assurance of carbon composite products for 10 years. When asked about the hopes to tackle in the future, he replied that he wants to handle training the next generation.
“Since carbon composite products have a high degree of freedom in design, it is difficult to establish clear standards for the inspection of carbon composite products that have such free shapes. When I have a problem, I try to resolve it while consulting with the Design Development Department, but the person in charge cannot fulfill their necessary role unless they can propose a measurement method by simply glancing at the drawings. As more and more products are likely to require precision measurements by coordinate measuring machines from now on, we aim to train the members of the Quality Assurance Department to give them the skills that they will need in the future,” he explained.
Toray Carbon Magic is a leader in the carbon composite product market that strives continuously towards the future.
|
|
