Extend Mold & Tool Life 10x Beyond Coating Limits with “Alpha Treatment®”

“I want to reduce the frequency of mold maintenance.”

“Even with coatings, the film peels off quickly and doesn’t last.”

“I want to improve sliding performance without using oil, but I can’t alter the dimensions.”

If you’re facing these kinds of challenges on the manufacturing floor, there’s one more solution to try before changing materials or designs: “Alpha Treatment®”, a proprietary surface modification technology developed by Fuji Manufacturing Co., Ltd. Below we explain how this technology distinct from conventional shot peening can extend mold and tool life, share quantitative evidence, and show how to implement it with minimal risk.

What is Alpha Treatment®?

Alpha Treatment® is a patented process that uses a proprietary air blast method to create micro-textures (fine surface irregularities) and nano-scale crystalline structures on metal surfaces at the same time. By modifying the metal’s outermost layer, it delivers these 3 effects simultaneously:

1. Balancing Strength and Toughness (Enhanced Wear Resistance)

Nanocrystallizing the surface layer (grain size 100–300 nm) increases hardness. Data shows hardness rises about 40% on SKD11 and about 30% on NAK80 versus untreated samples.

2. Improved Sliding Performance (Enhanced Lubricity)

Micro-textures reduce contact area and friction. The tiny recesses also act as “oil pockets,” improving lubricant retention, reducing wear, and helping prevent galling/seizure.

3. Outstanding Dimensional Accuracy Without Rounding Edges

Conventional shot peening can blunt edges, but Alpha Treatment® uses ultra-fine media to modify surfaces while preserving edge geometry.

[Verification Data: Edge Radius Change in NAK80 Material]

・ Before Treatment: R 9 µm

・ After Alpha Treatment: R 9.7 µm (virtually unchanged)

・ After Conventional Fine Particle Peening: R 29.6 µm (significant rounding)

As shown, Alpha Treatment® can be safely applied to precision mold parting lines and cutting tool edges. Moreover, it can be performed over hard coatings such as DLC or chrome plating without delamination, making it effective for extending coating life.

Case Studies: Tangible Results in Extending Service Life

In Thailand’s automotive and electronics industries, more success stories like the following are being reported:

・ Precision Press Dies: tool life >10×

・ Precision Drive Components: durability >5×

・ Cutting Tools: durability >60%, with reduced adhesion when machining difficult-to-cut materials

・ Rubber Molds: improved release reduces scratches/tearing; enabled mass production without release agents

・ Plastic Molds: insert life >10×, and contamination buildup on screws significantly reduced

※Actual performance may vary depending on conditions.

Experience the Benefits Firsthand with a Test Processing

“Is it really effective? I want to test it on our own workpieces.”

“We don’t yet have the budget or space to install new equipment.”

In such cases, take advantage of Fuji Blastech (Thailand)’s test processing service.

Implementation Steps

・ Trial (Test Processing): Contact our demo center in Samut Prakan, Thailand, and bring your workpieces. Our specialists process them under optimal conditions.

・ Validation: Evaluate results on your production line (tool life, product quality, etc.).

・ Decision: If satisfied, choose Job Shop services for occasional needs or consider dedicated equipment for mass production.

Catalog Download & Inquiries

If you’re facing issues with mold/tool lifespan or sliding performance, we encourage you to review our materials. Through the links below, you can download a detailed technical catalog or request a free test processing (details subject to consultation).

[ Download the Alpha Treatment Catalog ]

[ Inquire About Test Processing or Job Shop Services ]

We look forward to hearing from you.