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Utilizing new Super Micro-Grain Carbide with high durability, FW60

Kyocera Releases Ceraknife®

An industrial precision knife with double the durability of conventional products

April 19, 2007

Kyocera Corporation (President: Makoto Kawamura) is pleased to announce development of a new material, FW60, which features double the durability (in terms of resistance to chipping) compared with the company's conventional products. A new industrial precision knife, Ceraknife, will be released using this new material.
Industrial precision knives are used in the slitting/cutting process of all kinds of products and materials. This new product has exceptional durability, hardness and working life that provide consistent sharpness and allow it to be substituted for metal blades. In particular, because Ceraknife does not generate any burrs, dust or particles during the cutting operation, which are directly linked to device defects, it can be optimally used for the slitting process of functional polymer film, such as polarizing film and flexible printed circuit board (FPC), which are used mainly for liquid crystal displays.


Outline of Ceraknife

Name of material

FW60 (Super Micro-Grain Carbide with high durability)
Application and use Used in the cutting process for functional polymer films
Production base Kagoshima Sendai Plant
Production target 10,000 units/year

This product will be exhibited at the Eighth Converting & Special Printing Machinery/Materials Conference and Exposition in Japan 2007 (CMM JAPAN & JSP 2007). From April 25, 2007 to 28, at Tokyo Big Site, East Halls 1, 2, and 3

In the processes for cutting components and materials for electronics products, such as films and sheets used for liquid crystal displays, the requirements are becoming increasing stringent, not only in relation to high-quality cut surfaces that are free of burrs and distortion, but also in terms of preventing dust and particles from being created during cutting and for uniform processing. This is because even a minute chip in a blade or a burr produced by non-uniform blade wear is directly linked to product defects.
As such, industrial precision knives used in the manufacture of electronics products are required to provide high-quality cut surfaces and to be hard-wearing and highly durable to ensure high-quality processing. The knives are required to remain sharp and resistant to chipping throughout their long life.

Product features
1. The development of FW60, highly durable super micro-grain carbide
The average grain size of FW60 (highly durable super micro-grain carbide), which has been developed as a new material for industrial knives, is 0.8 µm (1 µm = 1/1,000,000 m), which is significantly smaller than the regular 3-µm to 8-µm carbide grain size. Moreover, by optimizing the content of its metallic component, cobalt, Kyocera has succeeded in doubling the durability over that of the conventional products.
The use of FW60 makes possible a sharp blade with superior durability and facilitates quality and productivity improvements in the cutting processes.
2. Long life
The life of the industrial precision knife is measured by the time that the product can be used until the quality of the cut materials becomes substandard due to deterioration in the cut surface and by the cut length. Compared with conventional metal knives, this new product achieves a life that is extended by 15 to 40 times*1, which can only be achieved with this highly durable knife.
*1 The life depends on the material to be cut.

Comparison between polystyrene cut surfaces

Cross section view

Example of the use of Ceraknife
Ceraknife cuts by catching the cut material with its upper and lower blades.