Small lot production of castings | Comprehensive support from pattern design to shipbuilding copper alloy castings
Are you being turned down for casting thin cores (passages)? We provide consistent support from wooden pattern design to machining, and we also manufacture ship parts using CAC406.
Have you ever experienced difficulty finding a manufacturer for copper alloy castings for shipbuilding parts? This product has narrow internal passages, making it challenging to create cores, and they are prone to breaking or deforming under casting pressure, which increases the difficulty of casting while maintaining the passage shape. Manufacturers that outsource wooden patterns and cores tend to take longer to make shape modifications or reassess core strength. Karmo Casting handles everything in-house, from the design and production of wooden patterns and molds to casting, machining, and inspection. We use casting simulations to check the flow of molten metal and pressure on the cores in advance, allowing us to propose designs that minimize the risk of breakage even with narrow cores. Since we have five casting processes in-house, including those for copper alloys, we can select the optimal method based on material and shape. This product is an example of a shipbuilding copper alloy casting made from CAC406 material, consistently finished from wooden pattern design to machining while maintaining a narrow core (passage) structure. We are offering a technical document summarizing the break-even analysis by method and considerations for small lot production for free. Please download it from the link below.
basic information
【Mold Design】 Consistent in-house support from the design of wooden molds, metal molds, and cores (shape changes also completed in-house) 【Lot Size】 From 1 piece 【Casting Size】 50mm square to 1,000mm square / Minimum thickness 1mm (local) / 1.5mm (overall) 【Product Size】 250mm × 280mm × 200mm (Copper alloy castings for marine use) 【Core Support】 Capable of handling thin core (passage) structures. Pre-check of breakage risk through casting simulation 【Supported Materials】 - Copper Alloys: CAC406 / 403 / 502 / 301 / 302 / 303 / 702 / 703 (8 types) 【Casting Process】 In-house possession of 5 methods: sand mold / self-hardening / alkaline phenol / cold box / metal mold 【Machining】 15 units of 5-axis machining centers, 2 gantry-type MCs, 3 vertical MCs, 2 NC lathes 【Inspection】 2 contact-type three-dimensional measuring machines, 1 non-contact 3D digitizer (deviation 50-80μ) 【Certification】 ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2
Price information
If you provide us with drawings or actual samples, we will offer a free estimate. We will also conduct casting simulations to pre-verify the structure of thin cores (passages) and propose conditions that minimize the risk of breakage. Since we handle everything in-house from pattern design, we can keep the pattern costs and delivery times down even if a review of the core shape is necessary.
Price range
P2
Delivery Time
OTHER
The first production, including the design and manufacturing of molds and cores, takes a minimum of 3 weeks. The timeline may vary depending on the complexity of the core shape, so please consult us first.
Model number/Brand name
CAC406
Applications/Examples of results
【Industries Served】Shipbuilding / Automotive & CASE / Railways / Aerospace / Semiconductors & Communication Equipment / Robotics / Machine Tools / Agricultural Machinery / Power & Energy 【Delivery Achievements】 ■ Copper alloy castings for ships (CAC406 / thin core [passage] structure / comprehensive support from wooden pattern design to machining) ■ Copper alloy castings for power equipment (CAC406 / thin-walled, internal passage, and uneven thickness measures) ■ Oil filters for industrial machinery (AC4B-F / comprehensive support from wooden pattern design to machining / prototyping) ■ Cylinder cases for railway vehicles (AC4CH-T6 / complex shape with 6 cores / delivery time of 2 weeks) ■ Aluminum parts for agricultural machinery (AC4A-T6 / high precision finishing) 【Used In Such Situations】 - Rejected for casting with thin core (passage) structure - Request for support on thin-walled and internal passage shapes of copper alloy castings - Desire to achieve both wooden pattern costs and integrated production - Replication of parts with only physical samples and no drawings 【Achievement Scale】Over 500 prototypes 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.