Aluminum casting prototype | Shape evaluation with sand molds before die-casting molds, starting from one piece.
After creating the molds for mass production, if there are design changes, the molds will need to be redone. We will prototype one piece using sand casting to confirm the shape and ship it in as little as two weeks.
Mass production is planned to be done through die casting, but I want to confirm the shape before making the mold. If design changes arise after the mold is made, the costs and schedule for redoing it will be significant. However, I cannot find a supplier that can produce just a few parts for evaluation. This is a common concern in the development field. Die casting molds are expensive and take a long time to produce, making them unsuitable for just a few prototypes. If we use machining as a substitute, the unique thickness and draft angles of castings cannot be reproduced, leading to evaluations that differ from the mass-produced items. Karmo Casting designs and manufactures wooden patterns in-house and can produce evaluation parts starting from just one piece using sand casting. Because it is easy to make adjustments to the mold, we can quickly respond to modifications based on the evaluation results. We conduct machining and inspections using three-dimensional measuring machines in-house, and prototypes can be shipped in as little as two weeks. We have over 500 prototype and development achievements annually. Even at the stage where the mass production method has not been decided, you can consider mass production through sand casting or die casting based on the evaluation results. We are offering a free collection of VA/VE case studies summarizing cost reduction examples from prototyping to mass production.
basic information
【Application】Prototype for shape evaluation before moving to mass production methods such as die casting 【Lot Size】From 1 piece 【Prototype Delivery Time】As short as 2 weeks 【Prototype Achievements】Over 500 cases annually 【Casting Size】From 50mm x 50mm to 1,000mm x 1,000mm / Minimum thickness 1mm (local) / 1.5mm (overall) 【Supported Materials】Aluminum alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B 【Casting Processes】In-house capabilities for 5 methods: sand mold / self-hardening / alkaline phenol / cold box / metal mold 【Machining Equipment】15 units of 5-axis machining centers / 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) 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2 【Heat Treatment】T6 and others available
Price information
If you provide the drawings (along with 3D data if available) and the quantities needed for evaluation, we will give you a free estimate. Since the molds are made in-house, we can accommodate shape modifications after evaluation without incurring external mold costs.
Delivery Time
Model number/Brand name
AC4CH/AC4C/AC4B/AC2A/AC7A and other 10 aluminum alloys (prototype for evaluation before mass production)
Applications/Examples of results
【Applicable Industries】Automotive・CASE / Electrical and Electronic Equipment / Robotics / Industrial Machinery / Communication Equipment 【Related Achievements】 ■ Motor housing for automotive EVs (AC4B-T6) ■ Aluminum casting prototypes for electrical components (from 1 piece) ■ Aluminum cast parts for automobiles (complex shapes with small radii) ■ Aluminum cast processed products for control equipment (tapping and grooving in thin-walled structures) 【Used in Such Situations】 ・Want to confirm the shape before making a die-cast mold ・Need only a few castings for evaluation ・Substitutes for machining cannot reproduce wall thickness or slopes ・Plan to revise the shape several times based on evaluation results ・Want to verify strength with castings before deciding on mass production methods 【Achievement Scale】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.