Small lot production of castings | Comprehensive support from pattern design to aluminum sand casting
Isn't it ambiguous whose responsibility it is for casting accuracy and machining accuracy? We provide consistent support from pattern design to machining and guarantee precision.
Have you ever experienced the difficulty of not knowing whether the cause of defects lies in casting or machining for parts with strict requirements for both casting accuracy and machining accuracy, such as brackets for industrial machinery? When the casting manufacturer and machining manufacturer are separate companies, the machining side ends up individually addressing the dimensional variations of the castings, which takes time for feedback. If mass production begins while the boundary of responsibility for accuracy assurance remains ambiguous, it becomes cumbersome to trace the causes of defects. Karmo Casting handles everything in-house, from the design and production of wooden and metal molds to casting, machining, and inspection. By measuring dimensions both immediately after casting and after machining, we can reflect the trends of variations in the machining conditions, thus guaranteeing both casting accuracy and machining accuracy as a unified whole. By consolidating the point of contact, we can also quickly identify the causes when defects occur. This product is an example of an aluminum sand casting bracket made from AC4B-F material, where we provided consistent support from mold design to machining, including accuracy assurance. We are offering a technical document summarizing the break-even points by method and the approach for small lot production for free. Please download it from the link below.
basic information
【Wood Pattern Design】Consistent in-house response from mold design (shape changes also completed in-house) 【Response Quantity】From 1 prototype to mass production of 30 units per month We handle the transition from prototype to mass production with the same system 【Product Size】200mm×200mm×60mm (Aluminum sand casting bracket for industrial machinery) 【Accuracy Guarantee】Dimensions are measured both immediately after casting and after machining, guaranteeing both casting accuracy and machining accuracy together 【Supported Materials】 - Aluminum Alloys: AC4B-F / AC2A / AC2B / AC3A / AC4A / AC4C / AC4CH / AC4D / AC7A / AC8B (10 types) 【Casting Process】Self-hardening / Alkaline phenol / Cold box 【Machining】15 units of 5-axis machining centers, 2 gantry-type machining centers, 3 vertical machining centers, 2 NC lathes 【Inspection】2 contact-type 3D measuring machines, 1 non-contact 3D digitizer (deviation 50-80μ) 【Certification】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2 【Items to Prepare When Inquiring】 Drawings (STEP / IGES / PDF) or photos of the actual item. If there are no drawings, approximate dimensions, materials, and quantities are sufficient. We also accommodate NDA agreements.
Price information
If you provide us with a drawing or a sample, we will give you a free estimate. We can accommodate production starting from one piece, and by manufacturing the molds in-house, we can keep initial costs low even for small quantities. Since costs vary depending on the manufacturing method, we will also suggest switching methods from machining, die casting, or 3D printing. (For reference: switching from machining requires a minimum of 5 pieces, and switching from 3D printing requires a minimum of 2 pieces to achieve cost reduction.)
Price range
P2
Delivery Time
P4
The initial process, including mold design and manufacturing, takes a minimum of 3 weeks. It may vary depending on the required precision, so please consult us first.
Model number/Brand name
AC4B-F
Applications/Examples of results
【Applicable Industries】Industrial Machinery, Electrical Equipment 【Delivery Achievements】 ■ Brackets for Industrial Machinery Equipment (AC4B-F / L250×W180×H80) Guarantees both casting accuracy and machining accuracy through dimension measurement immediately after casting and after machining. ■ Housings for Industrial Machinery Equipment (AC4CH / L300×W600×H150 / Wooden Pattern, Sand Mold) Reduces machining allowance to prevent warping. Cooling metal is used in thick sections to suppress shrinkage cavities. ■ Casings for Industrial Machinery Equipment (AC4B-F / L300×W250×H200) Cooling metal is arranged to address shrinkage cavities in thick sections. 【Used in the Following Situations】 - Ambiguity regarding responsibility for casting accuracy and machining accuracy. - Time-consuming investigation of defects due to separate companies handling casting and machining. - Desire to achieve both wooden pattern costs and integrated production. - Replication of parts that only exist as physical objects without drawings. 【Achievement Scale】Over 500 prototype and development achievements annually. 5,000 items from 200 companies in the last 5 years. 【Out of Scope】 We do not handle cast iron or cast steel (we specialize in aluminum alloys and copper alloys). Please consult us for large castings exceeding 1,000mm square.
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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.