Sand casting | Choose from 5 methods such as green sand and self-hardening based on quantity and shape.
Even with an increase in quantity, the manufacturing method remains the same as in the prototype, and the unit price does not decrease. We can reselect from five methods, including sand casting, self-hardening, and die casting, accommodating production from one piece to mass production.
Entering mass production with the same method chosen during prototyping means that even as quantities increase, the unit price does not decrease. Conversely, ordering small quantities using a method intended for mass production results in heavy mold costs. This issue arises from a mismatch between the method and quantity in the procurement of castings. Each casting method has its own optimal quantity and shape. There are methods that require significant effort to achieve precision and methods that produce numbers by repeatedly using molds; the balance between mold costs and labor per unit varies by method. Manufacturers with only one method have no choice but to adapt projects to that method. Karmo Casting possesses five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and die casting. Prototyping can start from a single piece, and when quantities increase, the method can be reviewed, allowing for a transition to mass production within the same factory. Since wooden and metal molds are also designed and manufactured in-house, we consistently handle the remaking of molds when changing methods. Decisions can be made after comparing costs for each method, so if quantity forecasts change, adjustments can be made according to the current numbers. We offer a free collection of VA/VE case studies summarizing examples of cost reductions achieved through method reviews.
basic information
【Casting Process】 Five methods in-house: sand mold / self-hardening / alkaline phenol / cold box / metal mold 【Mold Production】 Design and manufacture of wooden and metal molds in-house 【Lot Size】 From 1 piece 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 Equipment】 15 units of 5-axis machining centers / 2 gantry machines / 3 vertical machines / 2 NC lathes 【Processing Accuracy】 Geometric tolerance ±0.03mm 【Inspection Equipment】 2 contact-type 3D measuring machines / non-contact 3D digitizer (deviation 30-80μm) 【Certifications】 ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2 【Heat Treatment】 Supports T6 and others 【Factory Tours】 Available even before contract signing
Price information
If you could provide the drawings, the annual required quantity, and the quantity per order, we will propose a construction method that matches the quantity and provide a free estimate. Since the balance between mold costs and the cost per unit varies depending on the construction method, please let us know if there are any expected changes in quantity.
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Model number/Brand name
AC2A / AC4A / AC4B / AC4C / AC4CH / AC8B and other 10 aluminum alloys and 8 copper alloys.
Applications/Examples of results
【Industries Served】Automotive/CAS E / Industrial Machinery / Machine Tools / Agricultural Machinery / Railways / Ships / Power and Energy 【Related Achievements】 ■ Aluminum parts for die casting (design solutions to minimize distortion without heat treatment) ■ Small-lot castings of various types (30 units per year, 10 units per lot) ■ Aluminum parts for agricultural machinery (AC4A-T6 / high-precision finishing) ■ Cylinder cases for railway vehicles (AC4CH-T6 / complex shapes with 6 cores) 【Used In These Situations】 - When transitioning from prototype to mass production and wanting to review the manufacturing method - When production numbers decrease, making the current method too costly - When wanting to reduce mold costs without compromising quality - When wanting to decide based on a comparison of costs for each manufacturing method - When wanting to determine whether to use sand molds or metal molds based on quantity 【Scale of Achievements】200 companies and 5,000 items in the last 5 years. 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.