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

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

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

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

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

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.

7. Market for Products Manufactured through Die/Mold in 2005
Market Category
Examples of Applied Products
Calculation Basis
Production Value (NT$100 million)
Civil industry
Furniture, toys, sports goods
Specific products
1,000
Chemical industry
Plastic & rubber products
3,410
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
2,750
Machinery
Various machine parts
1. Specific products, Ratio of product by mold & die is 70%
2,380
Transportation
Auto parts, motorcycle parts
1,900
Power equipment
Battery, switch element
225
Total
18,534

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

9. Demand of Die/Mold for Notebook Components
Casing, frame
(Aluminum, magnesium, die casting, sheet hydroforming)
IO terminal (stainless steel→titanium)
(precision stamping)
HDD Parts、 CD Yoke
（Press forging）
Plastic casing
(Injection mold)
Every Notebook requires about 50 sets of mold & die for mechanical and casting parts.(Excluding purchased parts, such as flat panel, hard disc, thermal module)
30um fine line
(Micro welding, hydro static extrusion)
Heat pipe with 0.5mm thickness
Battery can
(Deep drawing)
CPU, IC Thermal module
(Counter pressure, press forging)
Thickness precision<±0.015mm

10. 2. Why Die/Mold is an Important Basic Technology

11. Precision of Die/Mold Affects Product Precision
Class
Precision of Mold & Die
Precision of Finished Product
Components
Applied Industries V
±1μ
±10μ
Micro bearing components, micro fasteners, micro probe
Optical, precision machinery, 3C, bio-technology VI
± 3μ
± 30μ
Iron core, IC lead frame, lithium battery can, TO-Can packaging component
3C industry
III
± 10μ
± 80μ
Tank cover, fender, motor housing
Auto & motorcycle, home appliance II
± 20μ
± 150μ
Hardware, rivet, battery can
Daily goods I
Switch box, joint
Agriculture & industry

12. Parts Manufactured through Die/Mold
Global production value of connector:
US$ billion
Production value of connector in Taiwan: US$3.125 billion
Import value from Japan in 2004 US$0.31 billion
●Game machine（such as Sony’s PS2、Microsoft Xbox）
●MP3(iPod)
●Computer (Desktop, NB）
●Cell phone
●Digital camera
●PDA
●Printer
●PCMCI PC Card Kit
●Optical connector
●Automobile
●LCD TV
Connector
Classification of Connector
1.Rectangular(A)
2.Circular(A)
3.Memory card(A)
4.Board-to-Board(A)
5.FPC/FFC(A)
6.Coxial(B)
7.RF Coxia(B)l
8.Module(A)
9.Card Edge(A)
10.Antenna(B)
11.LAN(B)
12.ECU(B)
13.HID Lamp(B)
14.Board-to-Wire(A)
15.Optical(C)
PS：A-Domestic technologies are matured
B-Part of domestic technologies is matured
C-Rely on importation
Applied Products
Technical bottleneck
Forming parameters
Machining precision of mold & die
Tolerance control of die/mold parts
Assembly tolerance of die/mold

13. Technical Difficulties
Extrusion of battery can requires ten stages of die process and each stage can not tolerate any defect.
Too small
Too large
Too large
Too small
Material holding pressure
Die clearance
Punch R
Too large
Wrinkles on flange drawing
Breakage on punch
radius
Die center misalignment
Typical example of NG extrusion parts
Breakage on side wall

14. Surface Treatment and Heat Treatment
for Die/Mold
Proper heat treatment/surface treatment can prolong die/mold life. It then improve productivity and hence competitiveness.
IC packaging die
Previous method: Hard Cr electroplating
R&D result: Cr-flon treatment
Benefit:
Previous method had to clean mold for 2 hours after 500 shots. New coating upgrades to clean mold for 1 hour after 800 shots and increases die life for more than 50%.
Nitriding hot forging die for crank shaft of motorcycle/ion increases service life by 3-4 times

15. A+ Die/Mold Technology must Combine Theory and Practice
＊Die/Mold technology is an integral technology. It includes material flow, control theory, precision processing, heat treatment, surface treatment, structure/mechanism, heat dissipation and tribology as well as knowledge in forming machine.
＊Excellence in individual technology can not produce a good die/mold. It must take integral thinking, take care of every single element and facilitate good coordination among elements to complete a good mold & die. Therefore the ultimacy of mold & die technology is often considered more of an art than a technology.
Progressive die for precision terminal (280 pieces components) Component precision: 1-3μm Precision after mold & die assembly: 8μm

16. 3. Current Status of Taiwanese Die/Mold Industry
Die/Mold Structure
Ejection pin (Ⅱ)
Ejection pin
Ejection plate
Ejection pin (Ⅰ)
Die set
QFP-48 Press Die
Punch back plate
Punch plate
Punch plate
Ejection block
Upper die plate
Guide pin
Stripper die plate
spring
Stripper bolt
Die plate
Die insert

17. Contents of Generic Technology for
Die/Mold
Design
Manufacturing
Process
Material
Inspection/
Certification
Process design & simulation
Mold & die material specification
Mold & die structure/ mechanism
Mold & die stiffness/ strength
Product material forming property
Mold & die surface treatment
Mold & die heat treatment
Mold & die machining
Design & selection of surface treatment
Design and selection of heat treatment
Material selection
Measurement method
Design and selection of jig & fixture
Surface polishing
Machining process
Tools selection
Jigs & fixture selection

18. Comparison of Manufacturing Level for Domestic & Foreign Mold & Die
Manufacturing precision
Design capability
Product life
Inspection ability
Price competition
After-sale service
Production speed
Taiwan
Taiwan
USA
Japan
Germany
South Korea
South Korea
Mainland China
Singapore
others
Source: Taiwan Mold & Die Industry Association; MIRDC’s ITIS project

19. Taiwan still relies on import for precision die/mold
Industry must enhance basic technology to set up the
key technologies of ultra precision mold & die
dimensional precision ±1μm (every mold)
DVD, optical, precision elements of MEMS
dimensional precision ±1μm (mold)
Imported components
& parts exceeded
NT$200 billion
in 2003
尺寸精度±1μm (每m)
特徵精度0.1m
(Ex.): Production value of TFT-LCD
(V) 超精 密級
2002 (actual): NT$ 3500 billion
Characteristic precision 0.1μm
Characteristic precision 0.1μm
(Technical bottleneck of Taiwanese mold & die industry)
Ultra precision level
2006(target):NT$ 1 trillion 370 billion
(10家)
(Tech)
尺寸精度±3μm(每m)
dimensional precision ±3μm (everymold)
2002(actual):NT$1 trillion
（汽車零件、3C精密 薄殼產品….）
(IV)
Precision level
Auto parts, 3C precision thin-wall products
2006(estimate): NT$ 1 trillion
100
manufacturers
Casing of home appliances, stationery
(III)Secondary
precision level
（一般家電外殼、文具….）
（日用品、家具….）
(II)General level
Daily goods, furniture
Agriculture, industrial usage
（農、工業用途….）
(I)Cheap level
Total Number of Taiwan Mold & Die Manufacturers: 3,526

20. Current Status of Taiwanese Die/Mold Industry
＊Production value of Taiwanese die/mold industry amounted NT$50 billion in 2003, roughly accounting for 4.3% of total global production value. The production value ranked the 8th place in However, it took the 6th place in Additionally the ranking of production value came behind Japan, USA, Mainland China, Germany, Italy, France and South Korea.
＊Main competitive advantages of Taiwanese die/mold industry include quick production speed and excellent quality. Taiwan is second to Japan in Asia. The complete and flexible production system of Taiwanese mold & die industry is the target to be followed by other countries. In average, the price of Taiwanese mold & die is about 70% of that of Japan, while Mainland China is about 70% of Taiwan and South Korea is about 90% of Taiwan.
＊The import unit price of Taiwanese die/mold is 2~3 times of export unit price, indicating the technical level is required to be upgraded.
＊Taiwan has 3,500 mold & die manufacturers. In terms of technical level, less than 10 manufacturers can be classified as ultra-precision level (with size precision ±1μm), under 100 manufacturers can be listed as precision level (with size precision ±3μm). Regular mold & die facing the competition from Mainland China, Korea and South East Asia, its capabilities require to upgrade.
＊As product requires higher and higher precision, the domestic mold & die technology is not sufficient to meet the requirements so that the imported components & parts exceed NT$200 billion per year.

21. Problems Faced by Domestic Mold & Die Industry
＊The average number of employee for domestic mold & die industry is 12 persons. It relies on passing experience. It has weak theoretical base and insufficient R&D capabilities.
＊Transformation of Taiwanese product manufacturer is focused on R&D. In the development stage, die/mold is developed in Taiwan and is relocated to low cost area in mass production stage. Die/Mold manufacturer must enhance innovative R&D capabilities, basic technology, and talented people (Otherwise 40% of manufacturers, about 1,400 makers, is estimated to withdraw from market).
＊Some system manufacturers sets up its own die/mold shop as domestic die/mold makers are not equipped with the development capabilities. However, they also face the same problems, including the upgrading of basic technology, knowledge and talents.
＊ The capability in basic research to facilitate the development of die/mold technology becomes weaker and weaker in educational and research systems. The number of department, professor and graduate student to be dedicated to study of Ph. D and master thesis as well as B.S. program are gradually decreased.

22. Problems Faced by Domestic Die/Mold Industry—Can’t do or Won’t do
＊Ultra precision die/mold (dimensional precision ±1μm, V level) must be comprehensively upgraded from material, equipment, manufacturing process and inspection.
→Domestic die/mold industry has the difficulty to establish R&D by itself.
→MIRDC takes the leading role to invest and work with other academic & research institutes for joint R&D.
＊The basic technical data for precision die/mold (precision ±3μm, IV level) are not sufficient so the development time is too long and the cost cannot be controlled.
＊The establishment of basic technology, sponsored by government, will prevalently increase the assurance for development, shorten the development schedule, increase the development willingness and further facilitate the overall industrial upgrading.

23. 4. Strategies for A+ Die/Mold Technology
Develop the basic common technology for A+ die/mold to upgrade the domestic die/mold industry.
Definition of A+ die/mold:
● Precision requirements:
-- Precision level (IV level): ≦± 3μ m
-- Ultra-precision (V level): ≦ ± 1μ m
● Long life span
● High product yield rate: easy for use and maintenance
High product complexity: 3D profile or compound machining
Short delivery: delivery accuracy 95%

24. Development Strategy of Die/Mold Technology
Micro Die/Mold Project
Break through technical bottleneck
Provide common lab. and assist the development
Common/Basic Technology Research
V ultra precision level
Optical,
MEMS
Dimensional precision under 1 μm
10 makers
VI ultra precision level
Dimensional preciison under 3μm
Collaborative Development
Platform
100 makers
Auto, 3C
Knowledge database
Ⅲ secondary precision level
Manpower cultivation
Dimensional precision 3~10μm
Provide JDM environment
Bring about rapid upgrading of overall capabilities
200 makers
Home
Appliance
Ⅱgeneral level
10~20μm
Case Consultation
3000 makers
Daily
Goods
I cheap level
Total 3,500 makers

25. (Ultra-precision Level)
Development Strategy of Common/Basic Die/Mold Technology for A+ Die/Mold
Category
Purpose
Development Focus
Level IV Die/Mold
(Precision Level)
＊Increase the design & development speed
＊Collection of technical knowledge
＊Localization and make technology become knowledge
＊Set up the website of basic technology database
＊Compilation of cultivation materials for professional engineers
＊Conduct long term cooperation with academic sector
Level V Die/Mold
(Ultra-precision Level)
＊ Establish domestic supply ability of ultra-precision die/mold technology and assist the product makers to develop the next generation product
＊Study of material formability for micro parts
＊Study of fabrication technology for micro die/mold
＊Study of design technology for micro die/mold
＊Study of manufacturing process technology for micro die/mold
＊Develop technologies for localization of equipment modulus for application of micro/meso die/mold
＊International cooperation

26. Strategy of Establishing Common/Basic Technology for Precision Die/Mold
MIRDC:
－ Collect & compile technical information and identify the insufficiency
－ Study of localized technologies
－ Demonstration and promotion
1. Responsible for collection and analysis of the related basic technologies
2. Technical certification
3. Study of localized basic technologies
4. Set up promotion mechanism and network
5. Promotion and service providing
6. Integrate domestic academic & research resources, provide the services and assist the industry to upgrade
7. Set up, maintain and update the knowledge database website
8. Introduce foreign advanced technologies and facilitate them to be localized
※15-20% of annual budget is used to conduct the industrial & academic cooperation and international cooperation

27. Strategy of Establishing Common/Basic Technology for Precision Die/Mold (Cont.)
Academic sector: Set up localized knowledge and conduct manpower cultivation
1. Analysis and comparison of domestic & foreign mold & die machining and the related forming theoretical models
2. Practicability analysis and comparison for localization
3. R&D of applicable theoretical models for localization
4. Conduct long-term cooperation with non-profit organizations, set up focus research capabilities and become long-term R&D and service partner
Stamping die, forging die, material and heat treatment have been identified with specific manufacturers to discuss the details. The cooperative targets of injection mold, die casting mold, machining, inspection and knowledge database are still under discussion.

28. Strategy of Establishing Common/Basic Technology for Precision Die/Mold (Cont.)
Industrial sector: Provide technical information and verification services
1. Participate R&D led by institution with target on suppliers and equipment makers, such as machine tool maker, tooling factory, heat treatment plant, material manufacturer and software company.
2. Manufacturers actively provide their related technical information or corporation technology development program formulates the topics to locate the manufacturers to conduct the cooperative research.
3. Research results are included in knowledge database for public sharing.
4. If the industry, actually develops mold & die, is willing to share the results publicly, then joins the R&D of institution, otherwise conducts the related technical development through industrial technology development program.

29. Cooperation of Industry, Academic and Research Sectors for Ultra Precision Level Die/Mold
Through specific cases, MIRDC cooperate with product company, die/mold makers, equipment makers and other academic & research institutions to conduct systematic development.
Market analysis, forecast and specifications setup for new products with development potentiality
System Makers
MIRDC
Design Co.
（Design Dept.）
Academic
Institutions
Equipment
makers
Other
設備開發建置
Manufacturing technology R&D
Planning of manufacturing & assembly production line
Prototype and small batch production
Cultivation of manufacturing/mold & die technical talents
Establishment of product specifications
Design of prototype product
System simulation and analysis
Development and setup of equipment
Development and setup of equipment
Complimentary technical research
Basic research
Theory and simulation analysis
Setup of experimental equipment
Database establishment
Mass production and assembly
Technical evaluation and suggestion
Guide of manufacturing technology design
Prototype test

30. Benefits to the Industry
Knowledge database of common basic technology for die/mold
Shorten Development time
25-75%
Knowledge database of specific products
Save setup cost
NT$20-50 million
Shorten manpower cultivation time
10 years → 5 years
Education/training material for manpower cultivation
Increase confidence of developing new product
Save trial times to 2 times
Trial & Error → Theory & Prediction

31. 5. Conclusions
＊Die/Mold technology tremendously affects the economic development in the nation. It is the industry that is greatly supported for development by the advanced countries as well as developing countries. It is the industry to be developed in Taiwan.
Target: unit price of die/mold reaches 85% of that of Japan in 2010.
＊Die/Mold industry in Taiwan needs more theoretical bases and talents, which will enable the upgrading to precision level die/mold. Previous research did not offer too much assistance in the upgrading of overall industrial technology and the development of national competitiveness due to limited budget and talents.
＊The research of basic technology for from A to A+ mold/die, supported by government and compilation of knowledge-base and database will not only benefit die/mold makers, but also offer tremendous assistance to the industry which is to be transformed into design-oriented industry.
＊This project has gained excellent response. Currently MIRDC has conducted the research planning with some industry, academic and research institutions. In the future, the concerted effort will facilitate sound and smooth implementation of this project.

32. 5. Conclusions (cont.)
＊Common/basic technology for precision level die/mold is to collect & compile the domestic & foreign information and conduct R&D to modify and localize information. They can be used in manpower cultivation and in knowledge-base for collaborative development platform to speed up the development time.
＊Ultra precision level mold & die is the key for future product development. The comprehensive development of material, machining, manufacturing process, inspection and equipment is a key to the production of ultra precision die/mold. The development of ultra precision die/mold must have the concerted effort of industry, academic and research sectors. First specific vehicle product is to be developed. Then the whole industry is thus promoted and developed.

33. Attachment

34. Contents of Generic Technology
Category
Generic Items
Basic Technologies
Design
Material formability of work piece
Design & setup of work piece
Planning design and simulation analysis of working procedure
Mold & die structure/transfer and design & analysis of multi action module
Stiffness/strength design and analysis of mold & die (parts)
Formulation of mold & die material specifications
(Refer to material classification)
Precision control of mold & die assembly
1. Parameter research and design standards setup of forming process (blanking, bending, drawing, upsetting)
2. Research of material forming parameters (size effect, anisotropy, flow stress and lubrication) and database setup
3. Calculation of forming load (setup of empirical formula and application of FEA software)
4. Stress, stress analysis and design standards setup of mold & die (parts)
5. Synthetic mechanism & dynamic analysis

35. Contents of Generic Technology
Category
Generic Items
Basic Technology
Manufacturing
Setup of machining procedure
--Machining methods/equipment selection
(Cutting, grinding, non-traditional machining)
--Heat treatment and surface treatment of mold & die parts
(Refer to material classification and elimination of machining residual stress)
Design & manufacturing of jig & fixture
Selection, design and manufacturing of tools
Precision control of mold & die assembly
Surface polishing
1. Research and control of machining manufacturing parameters
2. Research and database setup of mold & die material cutting/machining
3. Setup of machining SOP for group mold & die parts (punch, die, ejection pin and guide pin)
4. Integration and application of CAD/CAM
5. Accumulated tolerance and allowance

36. Contents of Generic Technology
Category
Generic Items
Basic Technology
Material
Selection of mold & die material
Selection of heat treatment/manufacturing process for mold & die
Selection of surface treatment/manufacturing process for mold & die
1. Database setup of size effect and mechanical property for heat treatment
2. Database setup of physical property for mold & die material (thermal expansion coefficient and thermal conductivity coefficient)
3. Database setup of mechanical property for coating/hardening

37. Machining and Forming Equipment
Contents of Generic Technology
Category
Generic Items
Basic Technology
Inspection
Selection of measurement methods/equipment
Design & manufacturing of jig & fixture
1. Study and SIP setup of geometrical tolerance measurement technology
2. Research of on-line monitoring technology
Machining and Forming Equipment
High precision
Intelligent
Hybrid
Localization of key components & parts
……..
(In line with mechanical technology research field)

38. Mold & Die Industry Development Projects in Asian Countries
1.Common Ground of Mold & Die Industry Development Projects in Japan and Korea
－Enhance export competitiveness－mold & die industry supports the product development
－Government sponsors the research of future competitive ability: micro-fabrication, precision upgrading and intelligent
－Application of IT－shorten delivery and reduce cost
－Upgrade development capabilities of new technology and new product: new material forming and mold & die design & machining, new product development
－Cultivation of high class design talents
2. Mainland China
－Mold & die industry is continuously listed as national important industry
－Increase import tariff of mold & die tremendously
3. Singapore
－Allocate S$2 million to conduct the planning of TDM (PDM of mold & die industry) system
－Allocate S$3 million to conduct the cultivation planning of mold & die design & manufacturing engineers and invest S$500 million to set up precision machinery and mold & die cultivation system
4. Thailand
－With Singapore’s assistance, Premier directly supervises to develop the auto and its components & parts
－Allocate THB$60 million to conduct the cultivation planning of mold & die talents and estimate to invest THB$1.69 billion to cultivate 7,000 persons within 5 years

39. General Status of Mold & Die Development in Japan
Ultra small
Semi-conductor lead frame
Asperical lens
Chip for penny motor, precision tube
Ultra large
Sheet metal for automobile
Large TV display of next generation
High precision
Stamping parts for auto body
Window of mobile phone
Complicated type
Module products (structure parts for automobile)
Forming in multi-color (front light of automobile)
Development factors
Abundant Creation (Design of auto door)
Assembly products
Long life & short delivery
More die stations
Die change is too often (mobile phone housing)
Strong mold & die design capability
Wide application (CD case, electronic products)
Strength of Japanese mold & die industry
Development of mold & die for ultra-fine, ultra-complicated, durable and high speed purpose
New emerging materials response to development of mold & die
Development of high speed & energy saving type machine
Development of hybrid special technology
技術力強化
短交期化/成本削減
海外市場開拓
超微細、超複雜、高耐久、超高速用模具開發
新興材料對應模具開發
高速省能源型機械開發
複合特殊技術開發
Source: Die and Mold Technology (Nov. 2004)/compiled by MIRDC’s ITIS project
Target of industry development
Enhance technical capability
Short delivery/cost reduction
Explore foreign market
Application of IT
Increase the design completeness of high class products

40. Development Project of Mold & Die Technology in Japan
Estimated amount: Japanese Yen 4 billion
Duration: 2003~2005(three years)
Application of automobile & industry machinery
汽車及產業機械應用
Casting die of high functional material
Thixomolding technology for high fusion point metal
Mold & die forming technology for new materials
Forging die of high functional material
Forming technology of flexible molds for poor machinability light metal
Plastic injection mold of new material
Development of exhaust part for high precision injection mold
For example: mobile phone battery housing/ SD memory card
RP/RT hybrid mold manufacturing technology
Main targets of development for mold & die machining technologies
如︰手機電池殼/SD記憶卡
Micro free curve & complicated shape, including aspherical lens/ micro remote device/hologram optical element
Required high precision/high speed transfer technology of DNA analytical instrument and high density LSI
DNA分析儀器及高密度LSI等所需高精密/高速大量轉寫技術
Ultra micro forming mold
Nano size mold & die forming technology
Ultra-precision/3 Dimension
Ultra precision plastic injection mold
Asymmetrical aspherical shape optical parts
Forming technology of complicated shape mold & die
High precision stamping die
Ultra-precision machining/measurement technology
Utilize ultrasonic micro/nano mold & die forming technology
High precision blanking of LSI lead frame
High precision extrusion of motor housing for CD ROM
High precision groove machining of fluid dynamic bearing for Hard Disk Drive(HDD)
Source: Die and Mold Technology (Nov. 2004)/compiled by MIRDC’s ITIS project

41. Mold & Die Technology Development Project in Korea
Policy Items
Detailed Contents
Infrastructure of Export Competitiveness Enhancement 
Infrastructure of Seoul and ultra-precision optical components cluster at specific district (Korean Won 1.5 billion in 2003).
Establishment of cultivation backup center for advanced countries type mold & die industry (Korean Won 1 billion in 2003): To support new product development through design, machining & measurement.
Cultivation of High Class Design Talents for Comprehensive IT Type
Backup of creative industrial education program (Korean Won 1.5 billion in 2003): To upgrade design capability of on-site personnel and creation of technical information exchange, increase the graduate of mold & die department in the university to join small & medium enterprises.
Development program of cultivation for Capstone Design talents (Korean Won 1.5 billion in 2003): Operation of combined course for comprehensive IT field .
Development of New Technology and Core Capability
Continuous promotion of “main infrastructure industry + IT industry” (Korean Won 8 billion in 2003): Plastic mold manufacturing technology and development of IT integration technology.
Source: Ministry of Commerce, Industry and Energy/compiled by MIRDC’s ITIS project

42. Development Target and Strategy of Mold & Die Industry in Taiwan
Production value of precision level mold & die makers doubles
NT$100 million
Future(2008)
IV & V class integration
mold & die, focus on mold
& die of the development
stage, number of mold & die
makers for precision level
doubles
Total production value
Strategic Measures
Implement industry’s type with focus on joint design & manufacturing (JDM)
800
Major Focuses
－Construction of collaborative design development environment
－Cultivation of design engineers
－ Assistance of IV level technical upgrading
－ R&D and promotion of V level technology
Current status (2004)
Traditional mold & die
technology of Ⅲ &IV class,
focus on mold & die for OME
product, about 100 mold & die
makers for precision level
566
2004
2008
Year

43. Analysis of Generic Technical Ability for Domestic IV Level Mold & Die
Category
Common Items
Industry
Design
Material formability of work piece
60 %
Design & setup of work piece
50 %
Planning design and simulation analysis of working procedure
70 %
Mold & die structure/transfer and design & analysis of multi action module
85 %
Stiffness/strength design and analysis of mold & die (parts)
80 %
Formulation of mold & die material specifications
Precision control of mold & die assembly
Manufacturing
Setup of machining procedure
75 %
Design & manufacturing of jig & fixture
90 %
Heat treatment and surface treatment of mold & die parts
Selection , design & manufacturing of tools
Precision control technology of mold & die assembly
Surface polishing
Material
Selection of mold & die material
Selection of heat treatment/manufacturing process for mold & die
Selection of surface treatment/manufacturing for mold & die
Inspection
Selection of measurement methods/equipment

44. Import Information of Import Components & Parts
Import Value in 2004
Unit: NT$100 million
Japan
Germany
USA
Total
Connector
100.1
6.6 (Singapore)
17.0
123.7
Lead Frame
57.0
20.0
(Singapore) － 77
LED Material
11.0
3.0(Singapore) 14
Optical Lens
7.1
1.4
5.0
13.5

45. Applied Industries of Components & Parts by Mold & Die
Global production value of
connector:
US$ billion
Production value of
connector in Taiwan:
US$3.125 billion
Connector
Foldable cell phone
1,3,4,5,6,7, 14
Cell phone
1,3,4,5,7
Notebook
1,2,3,4,5,6,8,9,14
LCD TV
Digital camera
1,3,4,5,6
Digital video recorder
Auto connector
10,11,12,13
Copy machine, printer
1,4,5,8,9,14
PDA
Plasma TV
1,3,4,5,8,14
DVD video recorder
Network communications
3,4,8,15
Technical bottleneck
-Forming parameters control of mold & die
-Machining precision control of mold & die
-Assembly tolerance control of mold & die
-Tolerance control of mold & die parts
Connector’s classification
1.Rectangular(A)
2.Circular(A)
3.Memory card(A)
4.Board-to-Board(A)
5.FPC/FFC(A)
6.Coxial(B)
7.RF Coxia(B)l
8.Module(A)
9.Card Edge(A)
10.Antenna(B)
11.LAN(B)
12.ECU(B)
13.HID Lamp(B)
14.Board-to-Wire(A)
15.Optical(C)
註：A-Domestic technologies are matured
B-Part of domestic technologies is matured
C-Rely on importation

46. Analysis of Basic Research for Generic Mold & Die Technology
Fish Bone Chart of Application for Deep Drawing Die Technology
Design and analysis of mold & die
Assembly and measurement of mold & die
Mold & die machining & manufacturing
Assembly platform
Size measurement
EDM
Machining
CAD technology
Material property
Assembly tools
Radius contour measurement
CAE analysis
Grinding
WEDM
Design database
Strip layout
CAM technology
Polishing
Process design
Measurement of surface coarseness
Deep Drawing Die Technology
Quick die change
Transfer press
Vacuum heat treatment
Ion nitriding
Safety device
Sensing technology
CVD
PVD
Transfer fingers
Feeder
Surface coating technology
TRJ
Lubricant selection
Trial and finished products
Heat treatment and surface treatment of mold & die

47. World leading institution World class institution
Main Development of Mold & Die Technology at MIRDC
(S & T Project)
Development of micro-fabrication
system
World leading institution
Development of production system
for value-added heightening products
World class institution
•Fine wire∮<17μm
L>300m/min
•Aspect ratio L/D > 8
•Optical pick-up head
•4mm prismatic batter can
Long copper probe
Domestic leading institution
R&D of system integration
technology
Domestic first class institution
•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
Increase industry
competitiveness
•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
•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
Construct development
infrastructure of mold & die
•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
Innovative mold & die
technology
Establish mold & die technology for generic
demand
Establish mold & die technology for generic
demand
Industrial application oriented
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004

48. Established Strategic Alliance with Academic & Research Sectors
Cheng Kung Univ.-Motor
－Analysis & Research of Thinning Design for Penny Motor
Yunlin Univ.-Micro EDM
－R&D of equipment & manufacturing process for micro EDM
MIRDC
Chung Hsing Univ.-Mirror Machining
－Use mirror machining system at Chung Hsing to jointly develop product and conduct industrial service
Kaohsiung Univ. of Applied Science-Optical mold & die
－Micro plastic injection mold technology
－Design and inspection of backlight module
－Cultivation of mold & die talents
Kaohsiung First Univ.-Mold & Die
－ MIM Research
－Technical consulting center of mold & die design & manufacturing process

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

50. Project Contents Explanation

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.

52. Generic Basic Technology of A+ Mold & Die
FY95(Framework setup)
FY96(Long-term cultivation)
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
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

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.

54. Expected Benefit in 2006
‧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 industry’s 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.

55. Working Contents and Index in 2006
Sub-Project
Output
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

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

57. Subcontract, etc (included)
Budget
Working Items
Current
Capital
Grand Total
Subcontract, etc (included)
Person-year
Original planning in 2006
54,000
6,000
60,000
13,000 20
Approved in 2006
34,000
40,000
7,200 13
Planning in 2007
76,000
4,000
80,000
14,000 30
Planning since 2008 (every year)
78,000
2,000 31
※ Subcontracting research includes the cooperation with industry and academic sectors under contract and international collaboration

58. Science & Technology Project Representative Contents
Labor of Division for Mold & Die Related Projects
Science & Technology Project
Main Contents
Representative Contents
Key Project
 Design, manufacturing, assembly & testing to develop micro products (components & parts made by micro mold & die)
 Penny Motor
 To-CAN，micro dual-in-line
 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
 Micro EDM module
 Mold & die of micro bearing
 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

59. Labor of Division for Mold & Die Related Projects (Continued)
Science & Technology Project
Main Contents
Representative 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
 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

60. Labor of Division for Targeted Work of Each Institution
Department of Industrial Technology
Industrial Development Bureau
MIRDC
Other 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 ※

61. Labor of Division for Targeted Work of Each Institution (Continued)
Department of Industrial Technology
Industrial Development Bureau
MIRDC
Other 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
Manpower Cultivation
Information setup by generic technology study provides the cultivation materials of mold & die talents and E-learning contents
Cultivation of design engineers
On-the–job 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

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