Integrated production from aluminum die casting to processing | Mass production of industrial machine parts
There are more than sand molds, but not in the quantities like die casting. We propose metal mold casting. We will handle everything from production to processing with 15 units of 5-axis machining centers.
There are many parts to be made with sand casting. However, it is not enough quantity to warrant creating a die-casting mold. Are you struggling to decide on a manufacturing method for parts that fall into this intermediate quantity range? With sand casting, a mold is created for each casting, so as the quantity increases, the labor and variability in the molds accumulate. On the other hand, die casting requires dedicated molds and equipment, making it difficult to recover mold costs if the quantity is uncertain. Parts that fall into this intermediate range tend to be more expensive regardless of the method used. The solution for this intermediate range is die-cast molds. Since the same mold is used repeatedly, the shapes are more consistent than with sand casting, making it suitable for parts with larger quantities. Karmo Casting is a foundry manufacturer that handles everything in-house, from mold design and production to casting, machining, and inspection. With five casting processes available, we can choose the appropriate method in-house, using sand casting for prototypes and switching to die casting when quantities are sufficient. After casting, we finish multiple surfaces using a five-axis machining center and verify dimensions with a three-dimensional measuring machine before shipping. We are offering a free collection of VA/VE case studies summarizing examples of weight reduction, cost reduction, and shortened delivery times, as well as a guidebook on casting defect countermeasures. Please download them from the link below.
basic information
【Scope of Services】Manufacturing of molds and wooden patterns / Casting / Machining / Integrated production of inspection (processing only; cutting of supplied materials is also acceptable) 【Lot Size】From 1 piece (same system from prototype to mass production) 【Casting Size】50mm square to 1,000mm square / Thinnest 1mm (local) / 1.5mm (overall) 【Supported Materials】 - Aluminum Alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 - Processing only: SCS13 / FCD450 / A5052 【Casting Processes】In-house capabilities for five methods: mold / green sand / self-hardening / alkaline phenol / cold box 【Machining Equipment】15 units of 5-axis machining centers (6 with pallet changers) / 2 gantry machines / 3 vertical machines / 2 NC lathes 【Machining Accuracy】Geometric tolerance ±0.03mm 【Inspection Equipment】2 contact-type 3D measuring machines / non-contact 3D digitizer (deviation 30-80μm) / 3D scanner NIMBLETRACK Gen2 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2
Price information
If you provide the drawings of the mass-produced parts (processing drawings are acceptable) along with the estimated quantities, we will offer a free estimate including the method for mold casting. Since we design and manufacture the molds in-house, there are no outsourcing costs or arrangement hassles. For small quantities, we can suggest sand casting, and for larger quantities, we can switch to mold casting.
Delivery Time
Prototypes can be shipped in as little as 2 weeks, while the initial production, including mold manufacturing, takes a minimum of 5 weeks. Mass production with molds will vary depending on the specifications, quantity, and processing locations of the molds, so please let us know your desired delivery date and quantity.
Model number/Brand name
AC4CH/AC4C/AC4B/AC2A/AC7A and other 10 aluminum alloys (die casting and mass production parts)
Applications/Examples of results
【Applicable Industries】Industrial machinery / Machine tools / Agricultural machinery / Robots / Semiconductor manufacturing equipment / Communication equipment / Ships / Railways / Automobiles & CASE / Power & Energy 【Achievements】 ■ Motor housing for automotive EVs (AC4B-T6) ■ Aluminum parts for agricultural machinery (AC4A-T6 / High precision finish) ■ Aluminum parts for ships (AC2A-T6 / Small size & mass production) ■ Base and pedestal for semiconductor manufacturing equipment (AC4CH) 【Used in these situations】 - Reduce dimensional differences in parts produced by sand casting and eliminate setup adjustments in processing. - Switch manufacturing methods from sand casting for prototypes to die casting for mass production with the same supplier. - Consolidate orders for dies, casting, and processing to one company to simplify mass production arrangements. - Produce the same parts with stable quality for each additional production run of the model. 【Achievement Scale】200 companies and 5,000 items in the last 5 years. Over 500 prototype and development achievements annually.
Related Videos
catalog（2）
Download All Catalogs
Recommended products
Distributors
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.