Molded aluminum cast parts, distortion countermeasures without heat treatment.
Considering the concerns about distortion, a material change is proposed instead of prototype testing. The mold casting contributed to reducing the risk of distortion and cutting costs.
Have you ever encountered any issues in the past during the prototype consideration before mass production? Our company has extensive experience from prototyping to mass production, and we propose optimal materials and methods to our customers by identifying concerns from drawings and data. Karmo Casting designs and manufactures wooden and metal molds in-house, which allows us to have a wealth of experience from prototype molds to mass production molds, and we support our customers in product development. We possess five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, and we select the optimal method according to quantity and shape. By confirming solidification and flow in advance through casting simulation, we can minimize the risk of rework even for small quantities. We provide consistent support from machining, inspection, to surface treatment after casting. Although there were special requirements for casting tolerances relative to product size, which demanded high precision, our sand castings can meet these high precision requirements, allowing us to fulfill our customers' requests. We offer a free technical document summarizing the break-even analysis by method and considerations for small lot production. Please download it from the link below.
basic information
【Supported Lot】From 1 piece 【Casting Size】200mm square to 200mm 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 units of 5-axis machining centers, 2 units of gantry MC, 3 units of vertical MC, 2 units of NC lathes / numerous achievements with geometric tolerance of ±0.03 【Inspection】2 units of contact-type 3D measuring machines, 2 units of non-contact 3D digitizers (deviation 30-80μ) 【Surface Treatment】Arrangements for plating, painting, anodizing, and impregnation (compliant with RoHS and REACH) 【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 molds in-house, we can reduce initial costs even for small quantities. Since costs vary depending on the manufacturing method, we will also suggest transitioning from machining to 3D printing. (For reference: transitioning from machining requires a minimum of 5 pieces, while transitioning from 3D printing requires a minimum of 2 pieces for cost reduction.)
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
AC2A-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, large quantities) ■ 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 wood 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 with only the physical item available and no 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.