Small lot production of castings | Consistent support from pattern design to production for industrial machine head covers.
Are you struggling with the timing of mold costs and transitioning to mass production? We provide comprehensive support from mold design to machining and will mass-produce the AC2A-F head cover.
Have you ever missed the timing due to the costs of wooden molds and adjustments with outsourcing when you wanted to produce small quantities of parts like head covers for industrial machinery? Manufacturers that outsource wooden molds often have separate contacts for mold makers and casting or machining manufacturers, which leads to additional adjustment costs and time every time there is a change in shape. In small-lot production, this burden of adjustments can pressure profitability. Karmo Casting handles everything in-house, from the design and production of wooden and metal molds to casting, machining, and inspection. We have five casting processes in-house: sand molds, self-hardening, alkaline phenolic, cold box, and metal molds, allowing us to choose the optimal method based on quantity and shape. By consolidating contacts, we can achieve short lead times and low costs even for small-lot production. This product is an example of a head cover made from AC2A-F material, handled consistently from wooden mold design to machining, accommodating small-lot production. We are offering a technical document summarizing the break-even points by method and considerations for small lot production free of charge. Please download it from the link below.
basic information
【Pattern Design】Consistent in-house support from design of wooden patterns and metal molds (shape changes and modifications are also completed in-house) 【Lot Size】From 1 piece to small-scale mass production 【Casting Size】From 50mm square to 1,000mm square / Minimum thickness of 1mm (local) and 1.5mm (overall) 【Product Size】400mm × 200mm × 100mm (head cover for industrial machinery) 【Supported Materials】 - Aluminum Alloys: AC2A-F / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B (10 types) - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 (8 types) 【Casting Processes】In-house capabilities for 5 methods: sand casting / self-hardening / alkaline phenolic / cold box / metal mold 【Machining】15 units of 5-axis machining centers, 2 gantry-type MCs, 3 vertical MCs, 2 NC lathes / numerous achievements with geometric tolerances of ±0.03 【Inspection】2 contact-type 3D measuring machines, 1 non-contact 3D digitizer (deviation 50-80μ) 【Surface Treatment】Arrangements for plating, painting, anodizing, and impregnation (compliant with RoHS and REACH) 【Certifications】ISO 9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2
Price information
If you provide us with drawings or physical samples, we will give you a free estimate. Since we handle everything in-house from mold design, we can keep mold costs and delivery times low even for small-scale production. When transitioning to mass production and increasing quantities, there may be further cost reductions through a review of the manufacturing method. Please consult us first regarding the shape and quantity.
Price range
P2
Delivery Time
P4
The initial process, including mold design and manufacturing, takes a minimum of 3 weeks. After transitioning to mass production, it can be shortened by reviewing the method. It varies depending on the shape and quantity, so please consult with us first.
Model number/Brand name
AC2A-F
Applications/Examples of results
【Applicable Industries】Automotive・CASE / Railways / Aerospace / Marine / Semiconductors・Communication Equipment / Robotics / Machine Tools / Agricultural Machinery / Power・Energy 【Delivery Achievements】 ■ Head covers for industrial machinery (AC2A-F / Comprehensive support from wooden pattern design to machining / Small-lot production) ■ Aluminum parts for agricultural machinery (AC4A-T6 / High precision finishing) ■ Cylinder cases for railway vehicles (AC4CH-T6 / Complex shape with 6 cores / Delivery time 2 weeks) ■ Copper alloy castings for power equipment (CAC406 / Thin-walled, internal passages, uneven thickness measures) ■ Motor housings for automotive EVs (AC4B-T6) 【Used in Such Situations】 - The cost of wooden patterns and the timing of transitioning to mass production do not align. - It takes time to coordinate between wooden pattern manufacturers and casting・processing manufacturers. - Only a few pieces are needed for prototype evaluation. - Replication of parts that only exist in physical form without drawings. 【Achievement Scale】Over 500 prototype and development achievements annually. In the last 5 years, 200 companies and 5,000 items.
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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.