Materials, Manufacturing and Performance Evaluation
Developing Polymer Components with Three Core Technologies
For polymer component challenges such as wear, noise, leakage and dimensional variation, STARLITE brings together material and geometry design, molding, machining, simulation and testing.
Our tribology expertise in friction, wear and lubrication supports sliding, braking, power transmission and sealing. Operating conditions and performance targets guide our approach from prototyping to production.
Three Connected Technologies for Your Development Challenges
Select and formulate materials, manufacture components, and verify performance. We connect these capabilities to develop solutions for each application.
Designing
Materials and Geometry for Target Performance
Polymer component performance depends on both material properties and component geometry. STARLITE considers materials, geometry and mechanisms together, based on operating conditions and functional requirements.
Challenges We Can Discuss
- Review alternative materials when the current material does not meet performance targets
- Explore polymer alternatives to metal parts or combinations of different materials
- Find material and geometry options suited to the operating conditions
- Coordinate material selection, prototyping and production through one development process
Material Selection & Formulation
We select base resins for the application and consider combinations of fillers and fiber reinforcements.
Material proposals reflect the required coefficient of friction, wear resistance, flexural strength, heat deflection temperature and electrical properties.
We also work on material development using biomass-derived feedstocks and recycled content.
Geometry & Structural Design
Our design work extends from component geometry that uses the material properties effectively to assemblies that incorporate surrounding mechanisms.
We consider thin walls, complex geometries, part integration and combinations with metal, with both function and production requirements in view.
Functional Design
For sliding, braking, sealing and power transmission, we develop materials, geometry and evaluation plans as a connected design task.
Performance targets guide the choice of component and mechanism configurations, while manufacturing methods inform the design.
Three Material Brands Supporting Our Design Capabilities
- BAKES
- Functional laminates based on phenolic resin
- ALP
- High-performance PTFE-based materials
- S-BEAR
- High-performance materials for injection molding
Processing
From Prototype Findings to Stable Production
Reproducing the intended performance in production requires careful process engineering. We consider component geometry, tooling and manufacturing conditions together, taking material behavior and molding shrinkage into account.
Challenges We Can Discuss
- Reduce dimensional variation and molding defects in production
- Select suitable processes for high-performance polymers or complex geometries
- Limit quality differences when moving from prototype to production
- Reduce part count and assembly work through component integration
- Develop large components or long products
Molding & Tooling Engineering
We consider injection molding, compression molding, laminate forming and extrusion according to the material and application.
Metal insert molding and polymer-to-polymer hybrid molding also support proposals aimed at reducing part count and improving assembly.
For high-performance polymers such as PEEK, our work covers material and process selection, mold design and production molding.
Process Engineering for Production Quality
Flow simulation and prototype evaluation help us assess warpage, shrinkage and dimensional variation.
We apply the findings to tooling, molding and machining conditions. Machining is incorporated where needed to support consistent dimensions, appearance and performance.
Manufacturing from Prototype to Production
We support prototype evaluation and the transition to production, taking the application and planned volumes into account.
Prototype findings inform production specifications to help limit quality differences during scale-up. Our proposals also consider stable supply through manufacturing sites in Japan and overseas.
Large Components and Long Products
We also manufacture seal rings and bearings with diameters of 1 m or more, as well as long, seamless products. Suitable manufacturing methods are reviewed against the material and product geometry.
Evaluating
Engineering decisions backed by analysis and testing
Friction and wear depend on material pairings, counterface materials, geometry and operating conditions. We combine analysis with testing to examine behavior and performance, then feed the results back into materials, geometry and manufacturing conditions.
The counterface material is the material of the mating surface in contact with the component.
Challenges We Can Discuss
- Identify design and molding issues before building a prototype
- Support design decisions with analysis and test data
- Investigate causes of wear, noise or leakage during development
- Reduce rework and development risks at an early stage
CAE Analysis & Verification
Computer-aided engineering (CAE) helps us examine behavior during manufacturing and operation.
Flow, structural, impact, thermal, heat-transfer and tribological analyses support the review of moldability, strength, noise and service life.
Experience from 7,000+ analyses over 30 years supports our product development and design work.
Performance Testing
We measure the coefficient of friction, wear, friction-related noise, leakage and heat generation to assess the required performance.
Test conditions are selected for the evaluation objective, considering temperature, contact pressure, lubrication and gas atmosphere.
Contact pressure refers to pressure at the interface between contacting surfaces. Evaluation methods and test conditions depend on the product and application.
Analysis & Visualization
X-ray computed tomography (CT), scanning electron microscopy (SEM) and image analysis help us examine defects and internal material structures.
We review molding defects, fiber orientation, internal voids and wear patterns, using the findings to inform design and process improvements.
We conduct CAE analysis as part of product development and design activities. We do not offer standalone CAE analysis services or perform analysis solely for third-party products.
From Your Initial Inquiry to Production Specifications
We connect the review of operating conditions with material and geometry design, analysis, testing and production specifications.
-
Review Operating Conditions
Review the application, counterface material, load, speed, temperature and operating media, together with current issues and performance targets.
-
Design & Analysis
Consider materials, geometry and mechanisms. Use analysis to compare concepts and identify development issues.
-
Prototyping & Testing
Evaluate performance under conditions relevant to the application, and apply friction, wear and other test findings to the design.
-
Define Production Specifications
Review geometry, tolerances, molding and machining conditions, and inspection requirements for production.
Frequently Asked Questions
Can we discuss material selection and component geometry together?
Yes. We consider material properties and component geometry together. Assembly design incorporating surrounding mechanisms can also be discussed, based on the application and the scope of your project.
Can you support both prototyping and production?
We support prototype evaluation through the transition to production. We review the material, geometry, required performance and planned volumes to discuss suitable manufacturing methods and development steps.
What information should we provide when contacting you?
Please share the application, operating conditions, current material, counterface material, observed issues and performance targets, as available. To send drawings, photos or specifications, follow the email instructions on our contact page.