Trial Production Contract Processing Special 2 | Contract Processing of Aluminum Castings for Semiconductors
We cannot find a processing destination for components for semiconductor devices. We accept machining only with the know-how of an aluminum casting manufacturer and will prototype in the shortest time possible.
Parts for semiconductor manufacturing equipment have high precision requirements, and have you ever experienced being turned down for prototype processing even when bringing in materials from other foundries? Castings have variations in shrinkage and internal stress depending on the material, and knowledge of casting is necessary for estimating processing conditions. The higher the dimensional precision required for parts specific to the semiconductor industry, the more difficult it is for manufacturers specializing in machining to make accurate estimates, often leading to delays. Karmo Foundry is a manufacturer that also casts aluminum castings in-house. With processing conditions estimated based on the trends of shrinkage and distortion of raw materials, along with high-precision processing equipment capable of geometric tolerances of ±0.03, we can handle machining contracts for raw materials intended for semiconductor equipment. We can accommodate a wide range of needs, from single units in the prototype stage to ongoing contracts after transitioning to mass production. This product is a compilation of cases where only machining contracts for parts for semiconductor manufacturing equipment were accepted, as part of our special feature on prototype contract processing. 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
【Processing Services】We accept machining of rough materials from other companies' cast products (utilizing our own foundry manufacturer's know-how) 【Quantity Supported】From 1 piece for prototypes 【Size Supported】From 50mm square to 1,000mm square 【Material Supported】General rough materials from other companies' cast products (mainly aluminum alloys such as AC4CH for semiconductor equipment) - Aluminum Alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B (10 types) 【Machining】15 units of 5-axis machining centers, 2 gantry-type machining centers, 3 vertical machining centers, 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) 【Certifications】ISO 9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2 【Items to Prepare When Inquiring】 Drawings (STEP / IGES / PDF) and rough materials (actual items). If there are no drawings, just dimensions and materials are sufficient. We also accommodate NDA agreements.
Price information
After confirming the material and shape of the cast metal, processing will begin in as little as 2 weeks. It may vary depending on quantity and precision requirements, so please consult with us first.
Price range
P2
Delivery Time
P4
After confirming the material and shape of the cast metal, processing will begin in as little as 2 weeks. It may vary depending on quantity and precision requirements, so please consult with us first.
Model number/Brand name
General raw materials of cast products from other companies (mainly aluminum alloys such as AC4CH for semiconductor equipment)
Applications/Examples of results
【Industries Served】Automotive/CASERailway/Aerospace/Shipbuilding/Semiconductors/Communication Equipment/Robotics/Machine Tools/Agricultural Machinery/Industrial Machinery 【Delivery Achievements】 ■ Prototype Contract Processing Feature (General raw materials from other companies' casting / Contracting only machining with aluminum casting manufacturer's know-how) Responding from a single prototype based on processing conditions considering material shrinkage and distortion. ■ Reverse Engineering of Industrial Machine Parts from Other Companies (AC4CH / Replication from 3D scanning without drawings, only physical samples) Shape measurement with the latest 3D scanner, reflecting shrinkage in mold design. ■ Brackets for Industrial Machinery Equipment (AC4B-F / L250×W180×H80) Integrated guarantee of casting accuracy and machining accuracy through dimensional measurement immediately after casting and after machining. 【Used in Such Situations】 - Unable to find a prototype processing partner for other companies' cast products. - Delayed due to equipment constraints of machining-only companies. - Need for processing estimates considering casting shrinkage and distortion. - Replication of parts with no drawings, only physical samples available. 【Achievement Scale】Over 500 prototype and development achievements annually. 200 companies and 5,000 items in the last 5 years. For large castings exceeding 1,000mm square, please consult us.
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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.