Method conversion | Transitioning from reduced production of die-cast products to sand casting and mold casting.
Although mass production has ended and the quantity has decreased, only the storage and maintenance of die-casting molds remain. We will switch to sand mold and die casting that match the quantity, accommodating from one piece.
The production quantity of parts that have been mass-produced through die casting has decreased, and they are now only made a few times a year as supplementary items. Nevertheless, the storage and maintenance of molds continue, and die casting manufacturers say that it is difficult to accept small quantities. This is a common issue that occurs in the latter half of a product's life cycle. Die casting is a manufacturing method that excels in mass production. Due to the significant setup required for molds and equipment, the cost per unit increases for small quantities. If the mold gets damaged, substantial repair costs may arise for a small number of items. Karmo Casting proposes to replace die-cast products with sand casting or mold casting based on drawings or actual items. We select the appropriate manufacturing method from five casting processes that match the quantity, and we also design and produce wooden and metal molds in-house. If there are no drawings, we can create a shape by 3D scanning the actual item. We conduct machining and inspections using a three-dimensional measuring machine in-house, accommodating orders starting from just one piece. Even if only a few items are needed as supplementary supplies each year, we will accept orders based on the quantity required at that time. We offer a free collection of VA/VE case studies summarizing examples of cost reduction through method conversion.
basic information
【Source of Conversion】Die-cast products (those with reduced production numbers and supply items) 【Casting Process】In-house possession of five methods: sand mold / self-hardening / alkaline phenol / cold box / metal mold 【Mold Production】Design and manufacture of wooden and metal molds in-house 【No Drawing Support】Measurement of actual items using 3D scanner NIMBLETRACK Gen2 【Lot Support】From 1 piece 【Casting Size】From 50mm square to 1,000mm square / thinnest 1mm (local) and 1.5mm (overall) 【Supported Materials】Aluminum alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B 【Processing Equipment】15 units of 5-axis machining centers / 2 gantry-type 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
Price information
If you could provide the drawings or actual items of the die-cast products along with the annual required quantities, we will propose the method and shape after the replacement and provide a free estimate. By switching to a method that matches the quantity, we can also reassess the burden of mold storage and maintenance.
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Model number/Brand name
AC4CH/AC4C/AC4B/AC2A and other 10 aluminum alloys (replacement from die-cast products)
Applications/Examples of results
【Applicable Industries】Automotive・CASE / Industrial Machinery / Agricultural Machinery / Electrical and Electronic Equipment / Machine Tools 【Related Achievements】 ■ Replication of parts without drawings (3D scanning → casting and machining) ■ Small-lot castings of various types (30 units per year, 10 units per lot) ■ Mold-cast aluminum parts (design solutions to minimize distortion without heat treatment) ■ Head covers for industrial machinery (consistent support from wooden mold design to small-lot mass production) 【Used in Such Situations】 - Production has ended, and only a small quantity is needed as a replacement part - Told by die-casting manufacturers that small quantities are difficult to accept - Want to reassess the burden of mold storage and repair - Do not have drawings for die-cast products - Want to arrange replacement parts in quantities as needed 【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.