Method conversion | Reducing costs by switching 3D printed parts to aluminum castings with two or more units.
Every time we need a 3D printed item, we create it, and the costs increase. By replacing the same shape with aluminum casting, we can reduce costs for two or more units and respond in as little as one week.
The shape has been determined with parts made by a 3D printer. However, as the number of evaluation units increases, the cost accumulates because each one is produced individually. With resin printed parts, the strength and heat resistance when integrated into the actual machine cannot be verified. This is a common concern we hear in the development field. Since 3D printers do not require molds, the first piece can be produced quickly and cheaply. However, the same effort and cost continue for each subsequent piece. Even when entering a stage where multiple units are needed, continuing to produce with 3D printing becomes more expensive than using a mold-making method. Karmo Casting replaces the shape of 3D printed parts with aluminum sand castings. Since we handle everything in-house from mold making to casting, machining, and inspection with three-dimensional measuring machines, we can provide parts made from materials close to the actual production. Transitioning from 3D printing allows for cost savings when producing two or more units, and we can respond in as little as one week. If you want to change the shape during the evaluation process, we can modify the molds made in-house, allowing for design changes to proceed with the same sense as with 3D printing. We are offering a free collection of VA/VE case studies summarizing examples of cost reduction through method conversion.
basic information
【Conversion Guidelines】Cost reduction when converting from 3D printers is applicable for two or more units. 【Delivery Time】The shortest delivery time for conversion from 3D printers is one week. 【Lot Size】From one unit. 【Casting Size】From 50mm square to 1,000mm square / Minimum thickness of 1mm (local) and 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 【Casting Processes】In-house capabilities for five methods: sand casting / self-hardening / alkaline phenolic / cold box / mold. 【Machining Equipment】15 five-axis machining centers / 2 gantry machines / 3 vertical machines / 2 NC lathes. 【Machining Accuracy】Geometric tolerance of ±0.03mm. 【Inspection Equipment】2 contact-type three-dimensional measuring machines / non-contact three-dimensional digitizer (deviation 30-80μm). 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2. 【Heat Treatment】T6 and others available.
Price information
If you provide us with 3D data or drawings along with the required quantity, we will offer a free estimate along with a shape confirmation for casting. The conversion from 3D printing is cost-effective for quantities of two or more. Since the molds are produced in-house, there are no outsourcing costs for the molds.
Delivery Time
Model number/Brand name
AC4CH/AC4C/AC4B/AC4A/AC2A and other 10 aluminum alloys (with internal water channels and high-difficulty castings)
Applications/Examples of results
【Industries Served】Automotive・CASE / Robotics / Industrial Machinery / Machine Tools / Semiconductor Manufacturing Equipment / Electrical and Electronic Equipment 【Related Achievements】 ■ Prototype aluminum castings for electrical components (from 1 piece) ■ Motor housing for automotive EVs (AC4B-T6) ■ Industrial machinery parts (AC4CH-T6 / complex shapes with 11 cores) 【Use Cases】 - The shape has been determined with 3D printed parts, but I want to verify strength and heat resistance with metal. - The number of evaluation units is increasing, and costs are rising if we keep using the printed parts. - Looking ahead to mass production, I want to quickly confirm if the shape can be made with casting. - I want to compare the costs of printed parts and castings based on the required quantities. - I want to use resin printed parts as metal components in actual machines. 【Scale of Achievements】In the last 5 years, 200 companies and 5,000 items. Over 500 prototype and development achievements annually.
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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.