R&D

Research & Development

The Spirit of Developers Passed Down from Generation to Generation

SK DEVELOPER SPIRIT

Believing in the potential of brushes and exploring the possibilities of meeting difficult challenges

A brush is a tool of simple construction made by implanting bristles on a wooden or resin base or by sandwiching a bundle of bristles between two pieces of metal. However, its followability and elasticity create a unique convenience not found in other tools. In Japan, brushes have been used as daily commodities since the early Meiji era (1868-1912) as well as in a wide range of industrial applications, including washing, polishing, shielding and water sealing, precision washing, and cushioning. They are used in various industrial fields ranging from steelmaking and civil engineering to medicine and semiconductors.
SHOWA INDUSTRIES is a manufacturer that believes in the potential of brushes and has been leading their evolution for half a century while sincerely responding to customer demands. From the very beginning, we have built a corporate culture of first gathering wisdom, considering and trying, based on the principle of “Never saying no to any request.”

Collecting a wide range of information and putting know-how and data in a database

Our engineers not only accumulate experience but also create flexible ideas by keeping their eyes open and gathering information. Furthermore, we are sharing knowledge internally by compiling a database of design documents, both successful and unsuccessful. We have been accumulating basic data obtained through material comparisons and product tests, visualizing and passing on skills and management methods, and collecting information at academic conferences and exhibitions. The tangible and intangible know-how accumulated in this way underpins our development, realization and proposal capabilities.

Providing supporting facts to functionalities through joint research

Some of our products are patented products that were developed through technical cooperation provided by us from the prototyping stage and joint research with inventors and universities. We enhance the credibility of our products by scientifically supporting the functionalities of our products and presenting papers at professional conferences.

Examples of papers

  • Flexible Fiber Conditioner for Fine Conditioning of Polishing Pad and Its Evaluation in Chemical Mechanical Polishing (2021 / International Journal of Automation Technology)
  • Research on Conditioning Methods for Polishing Pads with Ceramic Flexible Fibers (2018 / Proceedings of the Japan Society for Precision Engineering)
  • Research on Surface Roughness Regeneration Technique for Polishing Pads Using Flexible Fiber Conditioner and Elucidation of Its Mechanism (2016 / Proceedings of the Japan Society for Precision Engineering)
  • Evaluation of Effectiveness of Novel Pad Dressing Method by Flexible Fiber Dresser⎯Verification of Tool Life of Flexible Fiber Dresser⎯(2015 / Journal of the Japan Society for Abrasive Technology)
  • Evaluation of Effectiveness of Pad Dressing by Fiber Dresser and Its Mechanism⎯High-Speed In-Situ Observation of Fiber Behavior⎯(2015 / Proceedings of the Japan Society for Precision Engineering)
  • Evaluation of Effectiveness of Pad Dressing by Fiber Dresser and Its Mechanism⎯Life Evaluation Test of Fiber Dresser and Diamond Dresser⎯(2014 / Proceedings of the Japan Society for Precision Engineering)
  • Long Life Mechanism on a Flexible Fiber Conditioner in CMP (2014 / International Conference on Planarization / CMP Technology)
  • Evaluation of Effectiveness of Pad Dressing by Fiber Dresser (2014 / Proceedings of the Japan Society for Precision Engineering)
  • Evaluation of Stability of Dressing by Fiber Dresser (2013 / Proceedings of the Japan Society for Precision Engineering)

Unparalleled technical versatility

SK TECHNOLOGY

Responding to any manufacturing method, size and shape
All-rounder for brushes

SHOWA INDUSTRIES is a versatile brush manufacturer that covers channel brushes, roll brushes, twisting brushes and brushes made by any other manufacturing method. Our dedicated engineers design with flexible ideas and work with skilled craftspersons to manufacture products to your satisfaction. We are also as flexible as possible in processing into various shapes, bristle implantation in various materials, attention to detail and strict tolerances.

Integrated support for brush design and manufacturing One-stop service provided up to mass production

We have dedicated planning and sales staff members that serve as a single point of contact for each of our customers. They are well versed in the brush and manufacturing process and make proposals that meet the shape and function requirements. We provide integrated services, from design to production. Please contact us for OEM production and prototyping and testing of mass-produced products. We have the optimum supply chain with one-stop service, from material arrangement to manufacturing.

Passing on brush-making skills to the next generation

Brush manufacturing requires the use of a bristle implanting machine, forming machine and other facilities and equipment. Since it is difficult to fully automate these facilities and equipment in order to respond to small-volume, multi-variety production and manufacture custom-made products, much of the work is still done by hand by craftspersons. It takes several years to acquire a full range of skills, including bristle implantation, coiling and shearing, and many more years of experience to master a wide range of manufacturing methods. Bristle implantation is one of the most time-consuming processes to master, as it is difficult to control the number of bristles and feed them evenly. From the viewpoint of passing on to the next generation the work that used to be done with the “feel” or intuition of craftspersons and standardizing the quality that depended on craftspersons’ skills, we have established a bristle weight control standard and appointed technical instructors, thereby improving craftspersons’ techniques.

Fully equipped manufacturing and inspection equipment

SK FULL FACILITIES

Originally developed production equipment that achieves productivity and quality improvement

We have a department dedicated to the development of manufacturing equipment and jigs in addition to product development and design. We aim to continuously improve technology and productivity by developing original production equipment in-house that incorporates our original know-how and by providing technical guidance to the manufacturing sites.
In terms of quality assurance, we always strive to maintain and improve quality by conducting sampling checks by the engineering department as well as by carrying out quality inspections on the line. Our Head Office Plant has a large testing machine for measuring the durability and grinding performance of large brushes. In addition, we have introduced inspection equipment necessary for testing during new product development and improvement to produce products of reliable quality.

Fukuyama Plant equipped with a medical institution-level clean booth

Our Fukuyama Plant is equipped with a Class 100,000 (FED-STD-209E/ISO standard Class 8) clean booth. This is a facility with cleanliness at the level of medical treatment rooms and precision machine manufacturing. We meet the cleanliness requirements for cleaning brushes related to displays (LCDs, plasma displays and organic EL displays) and wash with ion-exchanged water, dry, finish, inspect and pack our products.

Manufacturing and inspection equipment

Classification Equipment name Number of units
Brush manufacturing Bristle corrugating machine 2
Bristle bundle cutting machine 4
Bristle bundle cutting machine (automatic) 1
Bristle blending machine 1
Channel forming/bristle implanting machine 14
Winding lathe 8
Winding device (automatic) 1
Bristle cutting lathe 9
Cup brush forming machine 2
Inside brush forming machine 1
Tubular brush manufacturing machine 1
Twisting brush manufacturing machine 2
Press Power press 3.5 t 1
Power press 5 t 2
Power press 15 t 2
Power press 20 t 3
Power press 25 t 6
Power press 35 t 4
Power press 1
Double hydraulic press 10 t 1
Hydraulic press 15 t 1
Hydraulic press 50 t 4
Hydraulic press 100 t 1
Corner shearing machine 1
Welding MIG welding machine 13
TIG welding machine 2
Arc welding machine 6
Spot welding machine 2
Inspection Balancing machine (dynamic balancing tester) 2
Image dimension measuring instrument 1
Digital dimensional measuring instrument 1
Other Machine lathe 2
NC vertical milling machine 1
Tabletop drilling machine 4
Radial drilling machine 1
Fine cutting machine 1
Laser marker 1
Washing equipment (washing, drying) 1
Testing equipment FFT analyzer 1
Hot water heater 2
Stroboscope 1
Digital thermometer 2
Roll brush tester 1
Microscope 1
Degausser 1
Colorimeter/color difference meter 1
Amplitude measuring instrument 1
Static meter 1
Electronic scale 1
Electronic balance 1
Surface roughness tester 1
Brush testing machine

Brush testing machine

Vertical 100-t press for disc plate assembly and compression

Vertical 100-t press for disc plate assembly and compression

High-speed and high-precision optical digital dimensional measuring instrument

High-speed and high-precision optical digital dimensional measuring instrument

FEATURES

  • Development Capability
  • Technological Capability
  • Proposal Capability

FUNCTIONS

Search products by application and function, such as cleaning, polishing and shielding.

PRODUCTS

SHOWA INDUSTRIES’ product lineup produced by a variety of manufacturing methods