Small lot production of castings, aluminum cast parts, industrial machine parts.
We can accommodate orders starting from just one piece, with production for around 30 items per year and a lot size of about 10 pieces. We have extensive experience with a variety of small quantity projects.
Have you ever been turned down by a foundry because you needed around 30 pieces a year with a lot size of about 10? The procurement of small quantities is a common issue faced by customers when selecting suppliers. The reason for avoiding small quantities lies in the costs of molds and setup. Manufacturers that outsource wooden and metal molds cannot reduce the initial costs for small projects. Karmo Casting designs and manufactures wooden and metal molds in-house, allowing us to keep mold costs and lead times low even for small quantities. We possess five casting processes: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, enabling us to choose the optimal method based on quantity and shape. By using casting simulations to verify solidification and flow in advance, we can minimize the risk of rework even for small quantities. We provide a consistent response from machining, inspection, to surface treatment after casting. We accept everything from a single prototype to mass production under the same system. We can also replicate parts that only exist as physical samples without drawings. We offer a technical document summarizing the break-even analysis by method and considerations for small lot production, available for free. Please download it from the link below.
basic information
【Supported Lot】From 1 piece 【Casting Size】250mm square to 300mm square / Minimum thickness 2mm (local)・3mm (overall) 【Supported Materials】 - Aluminum Alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B (10 types) - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 (8 types) - Heat Treatment: T6 and others available 【Casting Process】In-house capabilities for 5 methods: sand mold / self-hardening / alkaline phenol / cold box / die 【Machining】15 five-axis machining centers, 2 gantry-type machining centers, 3 vertical machining centers, 2 NC lathes / Many achievements with geometric tolerances of ±0.03 【Inspection】2 contact-type three-dimensional measuring machines, 2 non-contact three-dimensional digitizers (deviation 30-80μ) 【Surface Treatment】Arrangements for plating, painting, anodizing, and impregnation (RoHS and REACH compliant) 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2
Price information
If you provide us with drawings, physical samples, or 3D models, we will give you a free estimate. We can accommodate production starting from one piece, and by manufacturing wooden molds and metal molds in-house, we can keep initial costs low even for small quantities. Since costs vary depending on the manufacturing method, we will also propose switching from machining to 3D printing. (For reference: switching from machining requires a minimum of 5 pieces, while switching from 3D printing requires a minimum of 2 pieces for cost reduction.)
Price range
P2
Delivery Time
OTHER
Prototype shipping takes a minimum of 3 weeks. It may vary depending on the shape, quantity, and whether post-processing is required, so please consult us if you are in a hurry.
Model number/Brand name
AC4B-F
Applications/Examples of results
【Industries Served】Automotive・CASE / Railways / Aerospace / Marine / Semiconductors・Communication Equipment / Robotics / Machine Tools / Agricultural Machinery / Power・Energy 【Delivery Achievements】 ■ Cylinder cases for railway vehicles (AC4CH-T6 / Complex shapes with more than 6 cores / Delivery time 3 weeks / From 1 piece) ■ Aluminum parts for ships (AC2A-F / Small, high precision, mass production) ■ Aluminum parts for agricultural machinery (AC4CH-T6 / High precision finishing) ■ Copper alloy castings for power equipment (CAC406, AC4CH-F, etc. / Thin-walled, internal passages, uneven thickness measures) ■ Bases and pedestals for semiconductor manufacturing equipment (AC4CH-T6) ■ Motor housings for automotive EVs (AC4B-T6, A5052) ■ Resin wooden patterns for sand casting (Delivery time 7 days / From 1 type) 【Used in Such Situations】 ・Only a few pieces needed for prototype evaluation ・Single production of repair parts for discontinued products ・Shape evaluation before manufacturing die-casting molds ・Replication of parts that only exist as physical samples without drawings 【Achievement Scale】Over 500 prototype and development achievements annually. 5,000 items from 200 companies in the last 5 years.
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At Karmo Casting Co., Ltd., we engage in aluminum processing, aluminum casting, and the casting of copper alloys other than aluminum. Manufacturing has continuously supported the backbone of Japanese industry. At Karmo Casting, we have maintained that spirit and pride, dedicating ourselves to pioneering initiatives in the industry since our founding. Our primary goal is to build partnerships with our customers. To achieve this, we believe it is essential to flexibly adapt to changes in the times and realize all kinds of needs. Our relentless pursuit of technical expertise, responsiveness, quality, and speed reflects this attitude. While sensitively and swiftly understanding our customers' thoughts, Karmo Casting will continue to accumulate tireless efforts and changes as a manufacturing company that is chosen and needed by our customers.