Casting Dimensional Inspection | Quantifying Shapes with Two 3D Measuring Machines and a 3D Scanner
I don't know where the casting surface is misaligned, and there is residual black skin from the machining. Using two three-dimensional measuring machines and a digitizer with a deviation of 30 to 80 μm, I confirm the shape of the casting numerically.
Since entering machining, there has not been enough allowance for castings, leaving black skin. Even when using calipers during incoming inspections, it is unclear where the casting surface is misaligned. This is a recurring problem at the site where castings are purchased from outside. Castings shrink and may warp slightly as they cool and solidify, depending on their shape. While the machined surfaces can be measured, the often-curved casting surfaces are difficult to measure, leading to the next lot being processed without grasping the location and amount of misalignment. Karmo Casting measures the entire shape, including the casting surface, using two contact-type three-dimensional measuring machines and a non-contact 3D digitizer. In August 2026, a 3D scanner, NIMBLETRACK Gen2, was also introduced. By quantifying the misalignment and reflecting it in the correction of wooden patterns produced in-house and the establishment of machining standards, the entire process from casting to machining and inspection can be consolidated in one factory. The ability to distinguish whether the cause of the misalignment lies in casting or machining within the same company is a significant difference compared to ordering processes separately. We are offering a guidebook summarizing the causes and countermeasures for casting defects for free.
basic information
【Inspection Equipment】2 contact-type 3D measuring machines / non-contact 3D digitizer (deviation 30-80μm) 【3D Scanner】NIMBLETRACK Gen2 (introduced in August 2026) 【Machining Precision】Geometric tolerance ±0.03mm 【Machining Equipment】15 units of 5-axis machining centers (6 units with pallet changers) / 2 gantry machines / 3 vertical machines / 2 NC lathes 【Casting Process】In-house capabilities for five methods: sand casting / self-hardening / alkaline phenolic / cold box / molds 【Casting Size】50mm square to 1,000mm square / minimum thickness 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 【Lot Size】From 1 piece 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2
Price information
If you provide the drawings and the specific areas you would like to check during inspection (such as machined surfaces, casting surfaces, and allowances), we will provide a free estimate based on the inspection content combined with casting and machining. By addressing dimensional discrepancies in both the wooden mold and machining, we can reduce the remaining scale and rework in machining.
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Model number/Brand name
Aluminum alloy 10 types and copper alloy 8 types castings (integrated production of casting, processing, and inspection)
Applications/Examples of results
【Industries Served】Semiconductor manufacturing equipment / Aerospace / Robotics / Machine tools / Industrial machinery / Railways 【Related Achievements】 ■ Aluminum processed products for aerospace (thin-walled, small parts with a thickness of 3mm / JIS Q 9100) ■ Bases and pedestals for semiconductor manufacturing equipment (AC4CH) ■ Physical replication of parts without drawings (3D scanning → casting and machining) ■ Cylinder cases for railway vehicles (AC4CH-T6 / complex shapes with 6 cores) 【Applications】 - Insufficient machining allowance on castings, leaving black skin - Variability in casting surface dimensions by lot - Want to verify discrepancies between drawings and actual parts numerically - Casting and machining are outsourced to different companies, making it difficult to identify causes - Want to reflect measurement results in mold corrections 【Achievement Scale】200 companies and 5,000 items in the last 5 years. Over 500 prototypes 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.