The Three Core Technologies Behind Starlite’s Tribology
We engineer the polymer.
We mold it into the right shape—and produce it reliably.
We test it under field-like conditions—to prove it works.
Design it. Build it. Prove it.
That is how Starlite supports reliable motion behind the scenes.
A core capability that turns challenges into clear requirements —and moves proposals forward
01
Designing
Design for target performance—materials + geometry, engineered together
- Materials Design (Formulation)
- Geometry Design
- Function-Driven Design
02
Processing
Consistently reproduce designed performance in mass production
- Injection / Compression / Lamination / Metal-Polymer Hybrid Molding
- Precision Machining
- Prototype to Mass Production
03
Verifying
Validate performance with data—and optimize with confidence
- CAE Simulation & Validation
- Performance Testing (Tribology)
01
Designing
Design for target performance—materials + geometry, engineered together
Polymer components can’t be defined by material or geometry alone. At Starlite, we develop material design, geometry design, and function-driven design in parallel—to achieve both the required performance and manufacturability at scale.
Key Capabilities
1. Materials Design
Based on thermoset resins (including FRP composites), fluoropolymers, and engineering plastics, we combine organic/inorganic fillers and fiber reinforcements to tailor material performance to your application. We optimize key properties such as coefficient of friction (CoF), wear resistance, heat-deflection resistance, and electrical characteristics in accordance with operating conditions.
We also support the development of environmentally conscious materials through the use of biomass-derived feedstocks and recycled content.
2. Geometry & Structure Design
For requirements such as thin-wall designs, complex geometries, and part integration, we translate design intent into manufacturable structures—supporting metal insert molding, polymer-to-polymer hybrid molding, and even machining and assembly of large components. Our approach is always grounded in mass-production feasibility.
3. Function-Driven Design
For functional requirements such as sliding, braking, and sealing, we design materials × geometry × a validation plan as one integrated package. This allows us to propose clear specifications that meet required performance with confidence.
What It Solves
〇Replace metal parts to reduce weight and improve energy efficiency.
〇Prevent wear and seizure under harsh conditions such as high temperature, high load, and chemical exposure.
〇Reduce dimensional variation and defects in mass production to improve yield and consistency.
STARLITE Sub-brands
BAKES：Thermoset laminates for sliding and braking—heat and mechanical strength.
ALP：PTFE-based materials engineered for low friction and higher wear resistance.
S-BEAR：Injection-moldable engineering plastics for gears/bearings—low wear, stable production.
02
Processing
Consistently reproduce designed performance in mass production
To reproduce designed performance consistently in mass production, process design—molding and machining—becomes a decisive factor. At Starlite, we account for polymer behavior such as warpage and shrinkage, and design and control tooling (including mold design), molding conditions, and machining/finishing parameters. This allows us to translate requirements into production-ready specifications and process windows that can be reliably replicated on the manufacturing line.
Key Capabilities
1) Molding & Tooling Engineering
To shape difficult-to-process materials such as PEEK exactly as intended, we optimize proprietary mold design and molding processes. We translate flow simulation results into precise tooling structures, and select the best method—compression molding, injection molding, or lamination—to stabilize dimensional accuracy, appearance, and durability.
2) Process Window Design & Control (Molding × Machining)
Assuming polymer behavior such as warpage and shrinkage, we design molding and machining conditions as a coordinated set—while clearly separating what should be controlled in molding vs. finishing. We define production-ready specifications including tolerances, finishing requirements, and inspection criteria, so the same performance can be reproduced reliably in mass production.
3) Production System & Supply Design
We support everything from one-off prototypes to full-scale mass production. By coordinating our global manufacturing sites, we build a supply system designed to meet required quality and lead times with consistency.
What It Solves
〇Reduce dimensional variation and defects in mass production.
〇Achieve target shapes and performance with difficult materials and complex geometries.
〇Maintain quality when scaling from prototype to mass production—avoid performance drift during production ramp-up.
03
Verifying
Validate performance with data—and optimize with confidence
In tribological systems involving sliding contact, friction and wear performance can vary significantly due to the interaction of material pairings (including the counter-face), geometry, and the operating environment.
At Starlite, we first predict behavior through CAE simulation and then validate performance under real operating conditions at our in-house evaluation center. By integrating analysis (prediction) with testing (verification), we combine physics-based reasoning with measured data—providing a solid technical basis and leading to higher-confidence recommendations.
Key Capabilities
1. Analysis & Validation (CAE)
Flow simulation: Visualize molding risks in advance, including warpage and shrinkage.
Operating-condition simulation: Predict stress, deformation, contact pressure, and thermal behavior to verify design feasibility.
Parallel concept comparison: Evaluate multiple material and geometry options side-by-side to narrow down the best solution early.
2. Performance Testing
Testing that reproduces real operating conditions—load, speed, temperature, media/fluids, and counterface materials.
Quantitative measurement of wear (wear amount/rate) and coefficient of friction (CoF).
Identify dominant wear modes and isolate root causes of noise and vibration.
3. Correlation (Linking Prediction and Proof)
Correlate simulation outputs with measured data to update and improve model accuracy.
Feed results back into design to increase specification confidence and repeatability in production and in the field.
What It Solves
〇Reduce “we won’t know until we build it.”
〇Justify design feasibility with data-backed evidence.
〇Identify and eliminate rework and development risks early—before prototyping and tooling.
Design & Validation Process
- Define Operating Conditions
Load / speed / temperature / media (fluids/gas) / counterface material, etc - Pr-validate with CAE
Form a hypothesis → compare multiple concepts (materials/geometry) → identify the optimal solution early. - Prove It with In-house Testing
Test under application-relevant conditions → measure wear and coefficient of friction (CoF), etc. - Translate into Production Specifications
Specify geometry, tolerances, process conditions, and inspection criteria for repeatable mass production.
※Note: We conduct CAE simulations as part of our product development and design support activities. We do not offer standalone CAE analysis services (analysis-only requests), nor do we perform simulations solely for third-party products. Thank you for your understanding