Casting Defect Resolution Service - Aluminum Castings
We are struggling with casting defects at the current manufacturer... Our company has a wealth of case studies that address issues with casting defects.
Are you facing increased labor hours and delays in delivery due to quality issues with your current manufacturer, resulting in rework and remanufacturing? We often receive inquiries from clients who want to produce with stable quality and delivery times, but find it difficult to achieve improvements with their current manufacturer. On the other hand, changing suppliers can lead to changes in processes, so we also hear voices saying, 'I want to change, but the costs of molds and the setup time are obstacles that make it hard to take the plunge.' Additionally, we possess five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and die casting, allowing us to select the optimal method based on quantity, shape, and quality requirements. Furthermore, by utilizing casting simulations to confirm the flow of molten metal and solidification conditions in advance, we aim to reduce the risks of casting defects and rework from the prototype stage. We can consistently handle everything from machining, inspection, to surface treatment after casting, which helps alleviate the burden when changing suppliers. If you are struggling with quality improvements, delivery delays, or switching from your current supplier, please feel free to consult with us. We also offer free technical materials summarizing our know-how on casting defects and quality improvements. Please download them from the link below.
basic information
【Supported Lot】From 1 piece 【Casting Size】50mm square to 1,000mm square / Minimum thickness 2mm (local)・3mm (overall) 【Product Size】300mm square 【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 phenolic / cold box / die 【Machining】15 5-axis machining centers, 2 gantry-type MCs, 3 vertical MCs, 2 NC lathes / Many achievements with geometric tolerance of ±0.03 【Inspection】2 contact-type 3D measuring machines, 2 non-contact 3D 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, sample products, or 3D models, we will offer a free estimate. We can accommodate production starting from one piece, and by manufacturing wooden molds and metal molds in-house, we can reduce initial costs even for small quantities. Since costs vary depending on the manufacturing method, we will also suggest switching from machining to 3D printing. (For reference: switching from machining is cost-effective for orders of 5 or more, and switching from 3D printing is cost-effective for orders of 2 or more.)
Price range
P2
Delivery Time
OTHER
Prototype shipping takes a minimum of 2 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
AC4CH-T6
Applications/Examples of results
【Industries Served】Automotive・CASE / Railways / Aerospace / Marine / Semiconductors・Communication Equipment / Robotics / Machine Tools / Agricultural Machinery / Power・Energy 【Delivery Record】 ■ 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, large quantity) ■ Aluminum parts for agricultural machinery (AC4CH-T6 / High precision finish) ■ 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 ・Manufacturing single parts for discontinued product repairs ・Shape evaluation before producing die-cast molds ・Replication of parts with only the physical item available and no drawings 【Scale of Achievements】Over 500 prototype and development achievements annually. 200 companies and 5,000 items 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.