Innovative Design/Manufacturing
Technologies
New Production 2020 Project

Innovative Manufacturing — Manufacturing of New Function,
High Performance and Unprecedented High Added Value
In order to prevail against recent fierce international competition, businesses need to create high-value-added products.
The objectives of this program are to develop innovative manufacturing technologies leading to products comprised of
unconventional materials and functions satisfying a variety of personal and business needs, and to build a platform/system
where those technologies can be used. The goals of the program are for the creation of high-value-added products spurredby new ideas conceived through experiencing new technologies, and to strengthen Japan’s industrial competitiveness andrevitalize its regional areas.

ProfileProgram Director

Naoya Sasaki
Hitachi, Ltd.
Corporate Chief Engineer, Research &Development Group

Research and Development Topics
1 Research and develop innovative
production and manufacturingtechnologies

Dr. Naoya Sasaki joined Hitachi, Ltd. in 1982. He assumed the duties
of corporate chief engineer in 2014. Throughout his career, Dr. Sasaki
has been engaged in the development of mechatronic products andthe development and spread of mechanical systems technologies andmolecular simulation technologies. He holds a Ph.D. in engineering.
Dr. Sasaki is the chairman of the Japan Society of MechanicalEngineers.
He has been named a fellow of the Japan Society of MechanicalEngineering, and he has also been named a fellow of the Japan Society
for Computational Engineering and Science.
He is also a member of the Japanese Society of Tribologists.

•Approach to Innovative Manufacturing•Optimization Techniques(High-Value-Added Structure)•Simulation (Improved Efficiency)

AssistedDesign
Technologies

Platform forUtilizing
Tools/Technologies•P ositioning of Innovative ProductionandManufacturing Technologies•Use of New Materials•Fast, Flexible Prototyping
Product•Advanced, Complex
Functionality
Manufacturing and Processing

Innovative
Production andManufacturing
Technologies

Research and develop innovative production andmanufacturing technologies that make possible newMarketstructures, complex shapes, greater function, better
Users, Customers
quality and lower cost. Priority will be placed on
promoting 3D fabrication technologies aimed at theRealize high-value-added products,
diverse application of materials and the development
such as unprecedented new function andhigh performanceof new materials, and on functionality-addingtechnologies, such as bonding and surface treatment
technologies which add resistance or other diverse functionality.

Gradient Materials /Anisotropic Materials

Nano-ModifiedMaterials

Ultra-Micro Modeling
High-ValueAdded ProductsSuperEngineering
Plastics

Practical
Products

TitaniumAlloys Ultra-HeatResistant
AlloysBiomedicine /AircraftPrototypes

Mockups

Functionality-Added
Technologies

3D Fabrication Technologies

Soft
Matter

Surface Treatment

Molecular Adhesion ofDifferent Materials

Ultra-Low-Density,
High-Strength
Ceramics

Gel,
RubberBiomedicine / Aircraft /Nursing Robots / Sport

Ceramic Coating,
Metallic Coating, etc.

High-Precision
Modeling /Direct Modeling

Promising TechnicalFields
SIP Areas of TechnologicalDevelopment

Bio / Aircraft (Molds) /Filters

Conventional
Technical Fields
MetalsResin/High-Polymer
Materials

Ceramics

2 Research and develop assisted design technologies utilizing optimization and simulation

Research and develop technologies which make possible diverse functional design, based on needs, value and performance, as wellas high-quality product design, incorporating a variety of data such as production and manufacturing conditions. A particular focus
will be placed on strengthening and promoting assisted design technologies, such as simulation and optimization, with a goal ofrealizing high-value-added product design.

Implementation Structure
The Promoting Committee is chaired by the Program Director (PD).
The Cabinet Office serves as secretariat. The Committee is composedof relevant ministries, agencies, and experts who provide overall
coordination. This committee uses funds and management capacity
offered by the New Energy and Industrial Technology Development
Organization (NEDO).
The Committee has selected the best research and development
personnel as needed through open recruitment.

Cabinet Office PD (Naoya Sasaki)＜Promoting Committee＞
PD, Sub-PDs, METI, MEXT, NEDO,JST, Cabinet Office (Secretariat)

Operating Conference
PD, Sub-PDs

Strategy WG
Funding (Management) Agency

Sub-PD for Practical Application andRegional Revitalization
Mitsuo Nakatani(Panasonic Corporation)

NEDO

Advisor Sub-PD for Practical Application
Koji Yasui (Mitsubishi Electric Corporation)
Advisor Sub-PD for Regional Revitalization
Tetsuo Yoshimoto (Ritsumeikan University)

Practical application of outcomes: Practical application of tools, maximization of ripple effects
Regional revitalization: Building of sustainable platform/system (building of business models, etc.)

Sub-PD in Charge of Technology
Fumihiko Kimura(The University of Tokyo)

Sub-PD in Charge of Technology
Toshiyuki Obikawa(Tokyo Denki University)

Assisted design technologies

3D technologies,
functional modeling technologies

Collaboration among research topics through Strategy WG (participation in research topics),
general workshops (WS) and public symposia, etc.

50

Cross-ministerial Strategic Innovation Promotion Program (SIP)Develop tools from R&D results, provide technologies
Focus on more promising and advanced industrial areas, such as healthcare and the auto industry, as a technology area expected there, wefocus on functional addition technology such as 3D fabrication technologies and surface treatment/bonding technologies.
Provide tools/technologies to industry which contribute to their practical application in business, such as manufacturing equipment andsoftware.

Build a system for creating high-value-added products
Build a platform where regional SMEs and microenterprises can experience and use tools/technologies even after the end of SIP.
Enable businesses to create highvalue-added products, spurred by new ideas conceived through the experience.
In addition, provide SIP manufacturing network that domestic and foreign enterprises can access tools / technology one-stop.Continue
to provide advanced tools / technology on a one-stop basis through the WEB portal even after the end of SIP.

Efforts towards spreading
Development of database, data utilization, technology development aiming at improving usability of manufacturing equipment such as
3D printers developed for manufacturing technology of Society 5.0 era.

Progress to Date

Practical Application, Dissemination and Expansion of Tools/Technologies
In past research and development, the program has laid out the framework enabling businesses to utilize a number of technologies and tools that are
already at the practical application level.
For instance, the processing head comprising six superposed beams for use in laser coating, which was developed by the SIP research team led byProfessor Tsukamoto of Osaka University’s Joining and Welding Research Institute (JWRI), has been applied by the Yamazaki Mazak Corporation toits hybrid multi-tasking machines.
In addition, on November 1, 2016, D-Light Matter, Inc. (DLM) was established by a team led by Professor Furukawa of Yamagata University’s Life-3D
Printing Innovation Center (LPIC), as a means of creating business through the practical application of gel materials in devices based on the results ofSIP research and development.
Professor Nakano et al. Of Osaka University and Panasonic Corporation have developed a technology that demonstrates high functionality in therequired direction by controlling the atomic arrangement of metallic materials and improved the cooling characteristics of cold thermal devices by 70%
Achieve. And plan to develop and commercialize optical communication module Laser Diode temperature control and amusement machine from fiscal
2018.
In addition, Professor Nishiwaki of Kyoto University and Co., Ltd. developed a system that supports design planning based on topology optimization
for designers, a part of the technology for automatically converting the shape obtained as a result of optimization into CAD model was incorporated into
KUINTO's software and commercialized

Practical
applicationof a processing
headinused inPractical
applicationof a processing
head usedlaser coating
to a hybrid
multi-tasking
machinelaser coating
to a hybrid
multi-tasking
machine
Laser

Metal powder
Metal powder
Laser
Laser
Laser

Deposited Deposited
Dilution zone Melt pool Melt pool
Dilution zonezonezone

The 1st period Eleven Projects Key to the Rebirth of Japan and Its Position as World Leader

Exit Strategies

Practicalof high-performance
Thermoelectric
Practicaluse of use
high-performance
Thermoelectric
DeviceDevice
Customized
high-performance
ThermoelectricThe world's
Thefirst
world'sfirst ultra-compact
andCustomized
high-performance
Thermoelectric
ultra-compact
andDevice
Using Anisotropic
high-efficiency
Laser Diode(LD)Device Using
Anisotropic
Material Material
high-efficiency
Laser Diode(LD)module module
Thermoelectric Device
Thermoelectric Device

Thickness
1.6mm

Cooling Cooling
Development
Development
characteristics
characteristics
completedcompleted
in 2017 in 2017
UP70% UP 70%
Commercialized
Commercialized(comparedwith(comparedwithThickness
since2018
since2018
1.6mmconventional)conventional)

New LD module
New LD module
Thermoelectric
Thermoelectric
DeviceDeviceAnisotropic crystal
Anisotropic crystal

Multi-laser
metal deposition
Processing
head YamazakiYamazaki
Multi-laser
metal deposition
Processinghead
Mazak Mazak(new technology)
Corporation’s(new technology)
Corporation’s
hybrid multi-tasking
hybrid multi-tasking
machine machine

Establishmentof university-initiatedforEstablishmentof university-initiatedventureventureforgel printing
technology
world’sworld’s
first 3Dfirstgel 3D
printing
technology
a future
with soft materials
Create a futureCreatewith softmaterials

D-Light Inc.
Matter, Inc.
D-Light Matter,
Material
designMaterial
designDigitalDigitalprocessing processing

DigitaldesignDigital
designProductevaluation

Service menu
Service menu

90 degreeorientation

90 degreeorientationhigh performancebyRealizing Realizing
high performancebyaligning
crystal orientations
inaligning crystal
orientations
inrequired directions
required directions

Practical
applicationof automaticconversion
technology
Practical
applicationof automaticconversion
technology
of CADof CAD
with shape
optimization
model modelwith shape
optimization
AutomaticallytheAutomaticallyrecognizerecognize
theanalysis* surface
from the result
analysis surfacefrom the* resultof shape optimization
andof shape optimization
andautomaticallyit to CAD model
automaticallyconvert it convert
to CAD model
CAD model program
generation program
CAD model generation

AutomaticAutomaticconversionconversion

Product Water content:
Water
content: 90%
90%
evaluation

Analysis surface
Analysis surface

Breakingstress:
Breaking stress:
10-40
MPa 10-40 MPa

High-strength
gel 3D gel printer3D gel printer
High-strengthgelOptimal structure
Optimal structure

CAD ModelCAD Model*Analysis
surface(surfacethat can beby
represented
a numericalsuchcone,as cylinder,*Analysis surface(surfacethat canbe represented
a numericalbyformulasuch formula
as cylinder,sphere)cone, sphere)

Cross-ministerial Strategic Innovation Promotion Program (SIP)

51

Program Director

Naoya Sasaki Interview

Practical Application of Innovative Production
and Manufacturing Technologies, Centered
Around 3D Fabrication Using New Materials
The goal of this program is for manufacturing to achieve high added value, boosting the competitiveness of Japan’smanufacturing industry.
During the program’s final year, activities focusing on production and manufacturing technology, aiming at
commercialization of research results on some themes are accelerating.
In conjunction with this, we are promoting efforts to build places and mechanisms to utilize tools / technologies
developed to realize innovative manufacturing across industries, academia and government, trial use of external
users, and dissemination to the industry after the end of SIP.

Responding to Diverse Manufacturing Needs
This program aims to stimulate manufacturing and create
new markets supporting local economies, by linking business,
universities and public institutions together. The program primarily
promotes research that can be used by SMEs and microenterprises.
In terms of “innovative production and manufacturing
technologies,” we are looking at innovative manufacturing
technologies that take advantage of the specialized and unique
technologies owned by participating businesses and universities.
In particular, this program is focused on unconventional
nonferrous materials and production technologies (ceramics, rubber,gel, super engineering plastics, etc.) in which Japan already has acompetitive advantage. Here, researchers are developing materials
that offer new value, and creating products with unprecedented
complex shapes, functions and properties by means of various 3D
fabrication technologies as well as molecular adhesion technologies
which allow for different materials to be bonded together strongly.
As for “assisted design technologies utilizing optimizationand simulation,” we are establishing technologies that takefull advantage of innovative production and manufacturing
technologies, on the basis of techniques for statistically evaluating
diverse needs, topology optimization which allow structures andcharacteristics to be achieved that meet required specifications
while also satisfying various constraints, and manufacturing processsimulation technologies.
A number of technologies have already reached a level where
they can be utilized by business, such as the 3D gel printer and theprocessing head used in laser coating described on the previouspage. It is expected that other high-value-added products will
•Main Innovative Tools / Technologies
Resin
Photocurable -5μg
modelresin
Semiconductor Laser Ultra-MicroModeling

3D Rubber Shaping

3D Ceramics
ShapingFunctionality-Added

Initial shape

Healthcare Industry

Laser Direct
3D Anisotropic Reduction
Materials Shaping Drawing SystemFinger Model
Ceramic CoatingCustom shoes
Design tool

Needle Arrays forArtificial Blood Vessels

Surface
Treatment toImprove Sliding（Super Metal）

Laser Coating

Optimum shape

Prostheses
Design tool

Thermal Control Devices
Automotive
Connectors

Fabrication
Nano-Modified
Materials

Advanced Industries (Automotive, etc.)

False Teeth

Molecular Adhesion

Custom Implants Laser processing
Design tool
Simulation

Assisted Design52

Building on these outcomes, Program Director Naoya Sasaki
comments, “Since last fiscal years, by repeating a processof utilizing technologies in business, receiving feedback andfurther refining them, we have been promoting to improve theirdegree of versatility and perfection so that industry can employ
these technologies for high-value-added manufacturing.To thisend, for fiscal 2017 onwards,in terms of innovative production
and manufacturing technologies, the target areas linked to exit
strategies have been specified as future growth industries, thehealthcare industry offering new business opportunities, andthe advanced automotive and aircraft industries. A particularfocus has been placed on 3D fabrication technologies, centeredaround 3D printers as a technology creating new added value,
and on manufacturing technologies that add high value tocomponents and products, such as surface treatment and bonding.
As for design, the focus has been placed on technologies
utilizing optimization, which have liberated manufacturingfrom conventional constraints thanks to 3D printers, and on
technologies which support process design corresponding to new
manufacturing technologies.
Sasaki continues, “Japanese materials and components
manufacturers possess highly specialized technologies, as well as

Intraocular Lenses

3D Gel Shaping

Engineering Plastic Saping

Topology Optimization

Initiatives for Practical Application in the
Manufacturing Industry•Target areas

3D

Vulcanized UV Crosslinked Polyurethane
Rubberrubber
3D Superbe continue to be created using these technologies.As a new
manufacturing technology, we have also achieved results such as
the establishment of the basic technology for laser direct fabricationof the world's first ceramics that does not require sintering in afurnace.

Cross-ministerial Strategic Innovation Promotion Program (SIP)

Pistons
Artificial Joints

ProstheticLegs

Heat
Exchangers
Anisotropic,
High-Performance
Custom Implants

Ultra-High-Speed,
High-Performance
Communication Modules

New Production 2020 Projecthigh-quality, high-efficiency production/manufacturing techniques.
However, more than a few specialize in custommanufacturing
due to divisions of labor. To strengthen the competitivenessof Japan’s industries, it is important that regional SMEs andmicroenterprises be given advanced expertise from universities
and public institutions, and that they establish new methods andtechniques. To achieve this, an environment is necessary where theycan experience and utilize newly developed tools and technologies.
My hope is to provide for such a mechanism that can be maintainedeven after the end of SIP.”In this program, we are building a place to utilize the developedtools / technologies in the regional areas.
Sasaki continues, “For example, we opened a value co-creation
platform as a place to utilize newly at the Hyogo Prefectural
Industrial Technology Center, which supports SMEs in the Kobe
area where rubber is a local industry.
There, we installed the world's first vulcanized rubber 3D printerdeveloped by SIP and opened up as a tool for companies, users andresearchers to do manufacturing.”•Places Where Tools/Technologies Are Utilized(targets for end of fiscal 2018)

In this way, several tools / technologies have already been set up inlocal public testing institutes, testing of enterprises is proceeding,
and we are also promoting activities to promote regional industry
revitalization.
In addition, some tools / technologies are studying product sales
and service conversion by participating companies of SIP, "We havefinished it as a more versatile and practical tool through test use atcompanies. It is said.

Building Greater Potential for Japanese
Manufacturing•Concept of SIP Monozukuri Network
SIP Monozukuri Network
Achievement of SIP（Tools / Tchnology）
One-stopwindow(WEB Portal)

DomesticCompanies

ForeignCompanies

3D Fabrication
Technologies

Functionality-Added
Technologies

Assisted Design
Technologies

3D SuperEngineering
Plastic PrinterHybrid Ceramic
CoatingTechnology

TopologyOptimization

Rubber 3D PrinterSuper MetalTechnology

Individual
Adaptive
design Tool

3D Gel Shaping
SystemMolecularAdhesion
Technology

Laser Coating
Simulation

Platform for
UtilizingTools /Technologies

Healthcare
Industry

high-Value-Added
Products
Advanced
Industries

Innovation
Style

3D Printing Systems of Designable Gel
Molecular Adhesion Technology

Laser Coating System
Hybrid Ceramic Coating Technology

3D Rubber Printers ,Materials
Super-3D Fabrication Technology

Topology Optimization

Assembly of Nanomaterials•Sales Service of Tools / Technology (Plan)
Name of Tool

Business Consultation Company

3D Super Engineering
Plastic Saping PrinterASPECT Inc.

Shape Concept
Design System

Quint Corporation

CAD System for
Prosthetic Socket

Elysium Co.Ltd.

Multi Beam Laser
Coating Machine

MURATANI MACHINEMANUFACTURE Co., Ltd.

Rubber 3D PrinterKobe Material Testing
Laboratory Co., Ltd.

•Examples of utilization places: Hyogo Prefectural Institute of Technology
Value Co-Creation Platform
Technical Exchange Center【Collaborative laboratory】
3D Rubber Shaping, Shoe Design System etc.

HeaterNozzle【Industry, Academia【Seminar Room】
and Government Office】
Perform
Make meetings etc.
workshops etc.

3D Vulcanizedrubber PrinterXYZ axis table

3D Vulcanized rubberPrinter Prototype【Inner Sole】

The final year of the program celebrates,Sasaki continues,“Thanks to the efforts of the researchers, attractive tools andtechnologies for innovative manufacturing that have neverbeen done are coming up.Please do touch these tools andtechnologies.
To that end, we have built a SIP manufacturing network with
web-portals (http://www.sip-monozukuri.jp/) that can beaccessed on a one-stop basis for the tools, technologies andapplications that are the outcome.
Through these, a virtuous cycle is being promoted by industry
people to utilize the outcome, and the tools and technologies
that are results are further brushed up through utilization, andthey are brought up to
more attractive tools andtechnologies, after theend of SIP I would like tofinish it as a mechanism tocontinue.
I believe that the aboveis the strengthening ofindustrial competitivenessin Japan that this program
was aiming forand therealizationof regionalcreation.”

The 1st period Eleven Projects Key to the Rebirth of Japan and Its Position as World LeaderInnovative Design/Manufacturing Technologies

Produces various types of small quantities and complicatedshape forming without using molds
Can be expanded to products other than shoes

By establishing innovative manufacturing technology
using new materials and methods, building a place
to utilize that allows anyone to participate, and a
network that can access technology informationfrom anywhere, we will raise the underpinnings ofour country's manufacturing activities, and develop
regional innovation Contributing to.

Cross-ministerial Strategic Innovation Promotion Program (SIP)

53