Lightweight aluminum castings | Thin-walled design as thin as 1mm (local) from just one piece.
I want to lighten the parts, but I'm told that with castings, the thickness needs to be increased. For lightweighting, a thin wall of 1mm locally and 1.5mm overall is required, and prototypes can be made in as little as 2 weeks starting from one piece.
To lighten the equipment and vehicles, I want to reduce the thickness of the parts. However, when I consult with the foundry manufacturer, they tell me that they want it to be thicker because the molten metal won't flow properly. In the end, I have no choice but to make it thinner through machining, which increases costs. This is a concern I have from the design side. The difficulty in making the thickness of castings thinner is that the molten metal cools and solidifies before it can flow into the thinner areas. The greater the difference in thickness, the more likely the shrinkage will concentrate in the thicker parts, increasing the risk of defects. Karmo Casting has devised the arrangement of the pouring gate and the shape of the mold to accommodate local thicknesses as thin as 1mm and an overall thickness of 1.5mm. We confirm the flow of molten metal and solidification in advance through casting simulations, and since we design and manufacture the wooden molds in-house, we can consistently handle the review of shapes for thinning. Machining and inspections using three-dimensional measuring machines are also conducted in-house. The thinned areas are verified with a three-dimensional measuring machine and a non-contact three-dimensional digitizer, allowing us to confirm both lightness and dimensions numerically. We are offering a free collection of VA/VE case studies summarizing examples of weight reduction and cost reduction.
- Company：カルモ鋳工
- Price：Other
