Japanese Cutting-Edge
Solutions for Metalworking
Japanese Cutting-Edge
Solutions for Metalworking
News
September 12, 2025
By: Takuya Saito, Staff Editor, SEISANZAI Japan
Japan’s manufacturing sector continues to drive innovation in medical technology, where precision machining expertise directly supports healthcare advancement. As part of SEISANZAI Japan’s special coverage of companies applying advanced manufacturing techniques to medical applications, we begin this three-part series with CASTEM (Fukuyama, Hiroshima; CEO: Takuo Toda).
The company will present a remarkable demonstration of miniature surgical forceps at MECT 2025 (MECHATRONICS TECHNOLOGY JAPAN 2025; October 22-25, Port Messe Nagoya)—a palm-sized exhibit that packs decades of molding and microfabrication expertise into every microscopic detail.
Miniature forceps with fine knurling on the tip, to be displayed at MECT 2025
At MECT 2025, CASTEM will display functional miniature replicas of surgical forceps—instruments commonly used in laparoscopic surgery for grasping blood vessels and manipulating organs. Like their full-sized counterparts, the miniature versions feature fully operational handles and tips that move in perfect unison, allowing visitors to experience the mechanism firsthand.
The true showcase of technical mastery lies in the forceps tips, where precisely machined knurled patterns provide the gripping surface essential for surgical applications. Each diamond-shaped segment in the knurling measures just 0.231 mm wide and 0.085 mm high—dimensions that push the boundaries of manufacturing precision.
“This is where the real craftsmanship lies,” explains Yoichi Miura, Section Manager of Tooling Development. “Anyone can make a miniature forceps, but scaling down and faithfully reproducing functional knurling through microfabrication—that’s the true test of skill.” Miura holds Japan’s highest-level Tokkyū (Special Grade) national certifications in both machining and die manufacturing, representing the pinnacle of technical expertise.
Rather than attempting to machine the knurling directly onto the forceps, CASTEM creates high-precision molds that transfer the pattern with absolute fidelity, requiring no secondary finishing operations.
Mold machining for the forceps was carried out using ROKU-ROKU SMART TECHNOLOGY’s “Android II”; live demos at MECT 2025 will feature the successor “Android III”
The molds for the miniature forceps were precision-machined using the “Android II” micro machining center from ROKU-ROKU SMART TECHNOLOGY.
CASTEM introduced this specialized equipment seven years ago after experiencing inconsistent accuracy with conventional machining centers on micro-scale work.
“Previously, micro machining on standard machining centers produced unstable results with accuracy variations,” Miura notes. “The Android II eliminated those inconsistencies entirely.” At MECT 2025, live demonstrations will feature the latest “Android III” system.
The knurling operation employs ultra-fine end mills from NS TOOL, cutters as narrow as 0.1 mm in diameter. The complete machining sequence spans approximately 30 hours, requiring careful progression through cemented carbide roughing tools, CBN finishing tools, and finally PCD tools for mirror-surface finishing. Tool wear monitoring and frequent changes are critical throughout the process.
A unique challenge emerged in programming such microscopic features: CAM software introduced slight errors when working directly with miniature CAD models. CASTEM’s solution was ingenious—create the 3D model at 100 times actual size, generate the machining program, then scale everything down by 1/100 for actual production. This approach ensures programming accuracy regardless of the final part dimensions.
CASTEM leverages Metal Injection Molding (MIM) technology for manufacturing the miniature forceps components—a process the company has pioneered since the 1980s. Their dedication to MIM innovation led to a U.S. patent in 1991 for proprietary manufacturing methods.
MIM combines metal powders with binding agents, injection-molds the mixture into complex shapes, then removes the binder and sinters the parts to achieve final metal properties. CASTEM’s approach uses carefully optimized powder-to-binder ratios combined with precision molds to produce thin-walled, lightweight components with exceptional reproducibility.
“MIM-formed parts offer unique advantages in thin-wall, lightweight construction that are increasingly valuable across medical and other precision applications,” explains Executive Vice President Yuki Toda.
Recognizing the need to educate a new generation of engineers about advanced forming technologies, CASTEM has launched educational webinars covering MIM and lost-wax casting techniques. The company also conducts traveling exhibitions, bringing demonstrations directly to potential customers’ facilities.
“As Japan’s society ages, medical technology will only grow in importance,” emphasizes Executive Vice President Toda. “We see our MECT 2025 exhibition as a catalyst for expanding CASTEM’s recognition and partnerships in the medical field.”
・Dates: October 22-25, 2025
・Venue: Port Messe Nagoya
・Program: Live micro machining demonstrations with Android III system (by CASTEM)
・Location: Exhibition Hall 3, Concept Zone
・Demonstration Schedule:
Oct 22-23: 10:30 / 13:00 / 15:00
Oct 24: 10:30 / 12:30 / 15:00
Oct 25: 10:30 / 13:30
・MECT 2025 website: https://mect-japan.com/2025/en/
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