Method conversion | Integration of welded and assembled products with aluminum castings, prototype from one piece.
Welding sheet metal and machined parts together does not reduce the number of components or labor. By integrating with aluminum castings, we can prototype from a single piece, with over 500 prototypes produced annually.
We combine multiple sheet metal parts and machined components into a single structure using welding and bolts. Each part requires arrangement and inspection, and correcting the distortion from welding adds to the workload. As the number of parts increases, this burden becomes heavier. While the assembly structure can be started easily since each part can be made individually, the number of processes and management increases with the number of joints. Welding causes distortion due to heat, and there is also the task of readjusting dimensions after assembly. Karmo Casting proposes a method to consolidate multiple parts into a single casting based on the assembly drawings. We design and manufacture wooden patterns in-house, and incorporate ribs and mounting bases into the casting, which reduces the number of parts and welding processes. We perform machining and inspection using a three-dimensional measuring machine in-house after casting, allowing us to verify the shape and assembly with a single prototype before switching. For parts that are difficult to integrate, we do not force them into a single casting and include combinations of assembly and casting in our proposals. We offer a free collection of VA/VE case studies summarizing examples of cost reduction through integration and method conversion.
basic information
【Proposal Scope】Integration of welded structures and assembled products into a single casting (including shape proposals) 【Mold Production】Design and manufacture of wooden molds in-house 【Lot Size】From 1 piece 【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 【Casting Processes】In-house capabilities for five methods: sand mold / self-hardening / alkaline phenolic / cold box / metal mold 【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 Step 2 【Heat Treatment】T6 and others supported
Price information
The prototype will be shipped in a minimum of 2 weeks, and the first order, including the production of wooden molds, will take at least 3 weeks. The time may vary depending on the shape, material, quantity, and processing locations, so please let us know your required timing.
Delivery Time
Model number/Brand name
AC4CH/AC4C/AC2A/AC4A and other 10 aluminum alloys; CAC403 and other 8 copper alloys.
Applications/Examples of results
【Applicable Industries】Industrial Machinery / Machine Tools / Robotics / Agricultural Machinery / Railways / Shipbuilding 【Related Achievements】 ■ Aluminum machined frames for industrial machinery (large size, from 1 piece / ±0.03) ■ Industrial machinery parts (AC4CH-T6 / complex shapes with 11 cores) ■ Aluminum parts for agricultural machinery (AC4A-T6 / high precision finishing) ■ Aluminum castings for industrial machinery (thin-walled, small R, high precision shapes) 【Used in Such Situations】 - Welding and assembling parts made from sheet metal and machining - Spending time on correcting welding distortions - Wanting to reduce the number of parts to simplify procurement and inspection - Considering casting as an opportunity to review the structure - Wanting to eliminate the need for re-adjusting dimensions after welding 【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.