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.
- Company：カルモ鋳工
- Price：Other
