Hello. This is Chika from Machikoko staff.。
What is it usually like at the factory where the Petan stoves are made?
I've been allowed to go undercover every day recently, so I'll report on it in several parts.
Learning about the work and lives of factory workers has really excited me, as I love manufacturing.
This time, we'll introduce what kind of things we usually make.
Oh! Data for the flat stove.
"After designing it like this, we hand over the data to the person in charge of laser cutting."
At the place where I handed it over...
"We are setting up the cutting laser to cut the material according to the design specifications."
It's called CAM work. And next, let's look at the laser processing.
We're cutting metal sheets with a loud bang!
What are the most difficult aspects of setting up this laser cutting process?
"This is for adjusting the laser power. If it's too strong, it will melt into a gooey mess, and if it's too weak, it won't melt at all."
If the thickness is 2mm, we will adjust the settings to match 2mm thickness."
The pieces are cut like this and then bent to create the shape. Let's go see how it's bent! This is the machine that was used to bend the flat cases. (Reference:Previous report）
We asked a question to an employee (nicknamed "Shan-Shan") who has been with the company for four years and performs bending work every day.
What are you doing right now?
"We're testing sheet metal bending using a machine called a brake press."
When you bend metal, it expands and contracts slightly. We check for any misalignment or dimensional changes after bending, and adjust the fixing position and other details to the best possible conditions."
This bent shape was created by clamping it with a mold like this one below.
"The type of clamping mechanism used also varies depending on the bending angle, length, and thickness of the board."
This shelf has lots of different types, and I memorized them all in my first year."
What kind of difficulties do you face?
「It's the fact that things don't always go according to plan.For example, creating a gentle curved shape can be quite difficult.Indeed, "the craftsman's intuition and experience" are essential.So, I'm thinking about how to bend it and the order in which to bend it.
My senior colleague first taught me, "Don't think, feel."
That "craftsman's intuition" that you can't acquire just by reading books is so cool... I really admire it.
They also worked on machining each hole into a screw hole. (Left hole is before, right hole is after) Even a slight misalignment would result in an unsightly screw hole.
"This is a process called burring." This allows you to securely fasten it with screws!
Perfect!
Besides the "cut and bend" method, there's also the "make a mold and press the dough into that shape" method. This allows you to create more complex shapes! (For example, you can make the shape of a taiyaki (fish-shaped cake) using a mold, but it's difficult to make it by folding.)
I went to see the mold-making process. They design the mold themselves using CAD software and then make the mold on the spot.
Apparently, becoming a skilled designer requires not only experience but also a sense for visualizing three-dimensional space.
Then, using that mold, they deform the metal into complex shapes with a force of up to 1000 tons (!).
What are you doing?
"We check to make sure that the molded product isn't distorted or torn after it's been formed."
The prototype I just made warped and buckled when I pressed the center.
If the shape has many bumps and irregularities, the shrinkage of the metal will concentrate, causing a large change in shape.
I'm trying different things, like changing the mold I used earlier and altering the pressure I apply."
"How about we try changing it like this?" "Okay, I'll make a mold, wait a moment."
Watching their rapid trial-and-error process, their technical skills, and their teamwork, I was thrilled and envious.
Shape it, press and mold it, then cut it.
Their speed and technical capabilities are apparently difficult for other companies to imitate.
"Bring us projects that other companies have turned down."
That's what they tell their customers. It's proof of their high level of skill and confidence.
That's cool.
They also do welding, metalworking, and polishing.
Dealing with the challenges of metals, which are materials that expand and contract,
I often think, "He's a researcher who has accumulated intuition and experience."
I've been spending over a week at a factory that does various kinds of processing,
It's definitely worth watching. My introduction ended up being quite lengthy.
I'd also like to share some glimpses of the everyday life at this factory.
In this workplace, which handles even difficult orders as a "prototype sheet metal shop,"
Pettan CommunityWe'll turn your "I want this kind of camping gear!" ideas into reality.
Let's have a mini BBQ and make some camping gear together!
◆ 300% Celebration! We've added new rewards♪Click here for details on additional rewards.
◆ "Pettan Stove" was featured and reviewed on YouTube.Watch the video here
◆A revolutionary idea: a flat, compact stove! The "Pettan Stove" is a mini stove for one person that can be assembled in just one minute.The project page is here.
▼Crowdfunding campaign underway. We want to gather 100 people!▼
