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Application Case Studies of Metal 3D Printers in Die-Casting Mold Manufacturing
Special Seminar Report by Sodick × NIHON SEIKI
28/10/2025
Samurai Asia Editorial Department
On September 16, 2025, a seminar titled “Unconventional Future: The Possibilities of Molds × Additive Manufacturing (AM)” was held at Sodick Thailand’s First Factory.The event focused on the application technologies and case studies of metal 3D printers in mold manufacturing. The seminar was co-hosted by several partner manufacturers, including Nihon Seiki, a company in Japan that utilizes Sodick’s 3D printers for mold production, along with peripheral equipment suppliers. Together, they shared valuable know-how and practical insights on how to effectively utilize metal 3D printing technology. This was the first overseas seminar organized by Sodick that centered on metal 3D printing, and it attracted approximately 39 participants from 20 Japanese companies based in Thailand.
【Event Overview】
■ Theme
Cutting-Edge Case Studies and Quality Stabilization Strategies for Extending Die-Casting Mold Life and Driving Production Innovation through Metal AM Technology
■ Seminar Program
1. “Production Innovation through the Integration of Molds and Metal AM — Nihon Seiki’s Challenge in the ASEAN Region”
Speaker: Masato Matsubara, Managing Director, Nihon Seiki Co., Ltd.
2. “Introduction of Sodick’s Metal AM Technology for Molds and Its Latest Application Cases”
Speaker: Kenichiro Miyashita, General Manager, MC & AM Sales Division, Sodick Co., Ltd.
3. “How to Eliminate ‘Water Quality Troubles’ That Plague Molding Plants”
Speaker: Ryusei Nagasawa, Matsui Mfg. Co., Ltd.
4. “The World of AM — Japan’s Latest Trends and Subsidy Information”
Speaker: Hirofumi Koyanagi, President, Value Finder Co., Ltd.
■ Theme
Cutting-Edge Case Studies and Quality Stabilization Strategies for Extending Die-Casting Mold Life and Driving Production Innovation through Metal AM Technology
■ Seminar Program
1. “Production Innovation through the Integration of Molds and Metal AM — Nihon Seiki’s Challenge in the ASEAN Region”
Speaker: Masato Matsubara, Managing Director, Nihon Seiki Co., Ltd.
2. “Introduction of Sodick’s Metal AM Technology for Molds and Its Latest Application Cases”
Speaker: Kenichiro Miyashita, General Manager, MC & AM Sales Division, Sodick Co., Ltd.
3. “How to Eliminate ‘Water Quality Troubles’ That Plague Molding Plants”
Speaker: Ryusei Nagasawa, Matsui Mfg. Co., Ltd.
4. “The World of AM — Japan’s Latest Trends and Subsidy Information”
Speaker: Hirofumi Koyanagi, President, Value Finder Co., Ltd.
NIHON SEIKI: “Production Innovation through the Integration of Molds and Metal AM — Challenges in the ASEAN Region”
NIPPON SEIKI Co., Ltd.
A long-established aluminum die-casting mold manufacturer with over 100 years of history,
Nihon Seiki operates an integrated production system covering everything from design to manufacturing. The company launched its Additive Manufacturing (AM) division in summer
2021, and within about four years has achieved over 900 deliveries of AM-produced
components in Japan.
Speaker: Masato Matsubara
During the seminar, Nihon Seiki introduced multiple successful case studies of 3D printer applications in mold manufacturing.
Example:
By incorporating conformal cooling inserts (3D cooling channels) made possible through AM technology, the company dramatically improved traditional issues such as seizure during die-casting. This advancement extended mold component life by more than tenfold (over 40,000 shots) and increased productivity by 38%.
In addition to standard SKD61 powder, Nihon Seiki uses its proprietary HTC45 material, which offers higher thermal conductivity. To ensure quality and reliability, the company employs non-destructive analysis technology using 3D melt-pool visualization, enabling precise inspection of internal build integrity.
NIHON SEIKI aims to make AM technology a “standard specification” in mold design. To achieve this, the company is developing several innovations, such as:
- Chemical polishing techniques to improve surface roughness on down-skin areas after printing.
- Internal cleaning systems and solutions for cooling channels to restore performance to “as-new” levels.
- Looking ahead, the company is focusing on scaling up for larger components.
Using Sodick’s large-format LPM450 system, Nihon Seiki has successfully produced large water jacket parts and gigacast inserts, while also strengthening quality assurance through residual stress measurement during additive manufacturing.
Sodick: “Introducing Sodick’s Metal AM Solutions for Molds and Their Latest Applications”
Sodick Co., Ltd. Sodick is a manufacturing equipment company specializing in precision machining tools
and metal 3D printers, while also producing injection molding machines and industrial
machinery. In the metal 3D printer business, Sodick leverages its proprietary technologies
to integrate 3D conformal cooling channels into injection molding and die-casting molds,
enabling rapid cooling of complex geometries and high-precision builds.
Speaker: Kenichiro Miyashita
Sodick highlighted the core advantages of metal additive manufacturing (AM), emphasizing its ability to achieve effective temperature control and cooling in molds through the use of 3D conformal cooling channels. The company also presented examples demonstrating how metal AM enables the creation of complex geometries and rapid lead times that are impossible with conventional manufacturing methods. Sodick offers the OPM series, which integrates machining center functions, and the LPM series, which is specialized for molding and can mold in a low-oxygen environment. A particular strength is its proprietary SRT method (warpage control method), which suppresses warping and cracks, challenges that arise when molding molds.
By combining Sodick’s original SRT Method with its proprietary metal powder material “SVM”, the company has succeeded in achieving large-scale 3D printing for die-casting molds, a feat that was previously difficult to accomplish.
Successful Applications of Metal 3D Printing Expanding Across Southeast Asia
In the Southeast Asian region, the use of metal 3D printers is still in the early stages of development. Within the manufacturing industry, 3D printing remains a niche area, and opportunities to share practical case studies or technical know-how are still quite rare. Participants at the seminar expressed highly positive feedback, with comments such as “I didn’t realize the technology had advanced this far.”, “It was enlightening to see how broadly applicable metal 3D printing has become.”
Compared to other manufacturing machines, metal 3D printers require a deeper understanding of operating know-how — particularly in how to optimize their use for different manufacturing conditions. As a machine manufacturer, Sodick not only provides the equipment itself but also places strong emphasis on offering guidance and practical advice on how to implement and maximize the technology on the production floor. By applying the successful case studies and accumulated expertise from Japan to overseas mold manufacturing sites, Sodick aims to promote broader adoption of metal 3D printing in the ASEAN region and contribute to the overall advancement of the industry. 
▲ Sample parts manufactured using a Sodick metal 3D printer
▲ From left: Kenichiro Miyashita (Sodick), Masato Matsubara (Nihon Seiki), Hirofumi Koyanagi (Value Finder)
