Renowned Master Mold Polisher Hideki Kato Credited for Innovative Paintless Bumper Technology
In the heart of Toyota Motor Corporation's Mobility Tooling Division, master mold polisher Hideki Kato and his team have been perfecting the production process for the company's paintless bumpers. This meticulous work, which demands an unparalleled level of precision and attention to detail, showcases the fusion of traditional craftsmanship and modern technologies.
Unlike traditional cast molds, Kato uses forged molds to create the paintless bumpers. This process eliminates air cavities, ensuring a smoother finish after machining. The resin used for these bumpers is harder than standard materials, making it more challenging to work with but resulting in a glossy look.
Kato's polishing technique is nothing short of remarkable. He uses specialized gloves to detect surface irregularities as small as five microns. The polishing process removes imperfections down to two microns, achieving a mirror-like finish without scratches.
The production process, led by Kato, started from scratch when Toyota's first paintless bumper was introduced. His pupil, Chihiro Takeshita, played a significant role in this development. Takeshita is now creating video lectures to help young technicians learn the skills more efficiently.
However, the physical toll of the process, particularly on the fingers and wrist, became a major issue. Small holes were discovered in the machined mold, indicating an issue with the material itself. A harder steel with fewer impurities was needed to solve the problem, which was tracked down overseas.
After settling on the tools and process, the team had to revise their polishing process multiple times to achieve the target L-value for the paintless rear lower bumper. Subtle inconsistencies in the polishing process can affect the "L-value" of paintless plastic parts, requiring a delicate touch and uniform pressure.
The mirror-finish mold polishing process took around 800 hours in total, with the initial surface preparation being the most time-consuming part. The collaboration between Kato, Takeshita, Nitta, Toyoda, and Shimakata was crucial in the development of the paintless bumper.
Shimakata emphasizes the benefits of paintless parts, such as their smooth appearance and ease of repair. The team plans to attempt white components using the paintless technology in the future.
While modern technologies like AI and 3D printing can augment production efficiency and customization, they may not replicate the exacting standards required for paintless bumpers without significant investment in technology and training. Nevertheless, the story of Kato, Takeshita, and their team serves as a testament to the enduring value of traditional craftsmanship in the face of technological advancements.
[1] https://www.toyota-global.com/innovation/technology/mould/ [2] https://www.toyota-global.com/innovation/technology/paintless-bumpers/
- The fusion of traditional craftsmanship and modern technologies, as demonstrated by Kato's work on the paintless bumpers, is also evident in the video lectures created by his pupil, Chihiro Takeshita, to educate younger technicians about the process, merging the general-news of Toyota's innovation with the lifestyle of learning and passing down skills.
- As Shimakata emphasizes the advantages of paintless parts, the Toyota Motor Corporation's Mobility Tooling Division, using technology like AI and 3D printing, may aim to enhance production efficiency and customization in sports applications such as functional auto components, but the story of Kato, Takeshita, and their team shows that these advancements cannot replace the exacting standards required for creating paintless bumpers, highlighting the significance of traditional craftsmanship in the world of technology and sports.
