カルモ鋳工 Product Lineup

I want to machine brackets, jigs, and covers for devices from A5052 sheet material. However, due to the high number of surfaces, pockets, and holes, processing companies tend to be reluctant to take on small quantities. This is a common concern expressed by design and procurement personnel from equipment manufacturers. The labor-intensive aspect of multi-surface machining is the setup change required every time the orientation of the cutting tool is altered. In a 3-axis machine, it is necessary to change the setup for each surface, which increases both the time required and the variability in precision due to the need to re-establish reference points each time. Karmo Casting owns 15 five-axis machining centers, six of which are equipped with pallet changers. This allows us to reduce the number of workpiece changes and process multiple surfaces, thereby minimizing the setup burden even for small quantities, while achieving a geometric tolerance of ±0.03mm. Inspections are conducted using a three-dimensional measuring machine. If the volume increases and casting becomes more advantageous, we can also propose a transition to casting. By performing both machining and inspection in one factory, we can immediately reflect the measurement results in the next machining process, thereby reducing dimensional variability even for small quantities. We are offering a free collection of VA/VE case studies that summarize examples of cost reduction, including method transitions.

• Contract manufacturing
• Processing Contract

Since entering machining, there has not been enough allowance for castings, leaving black skin. Even when using calipers during incoming inspections, it is unclear where the casting surface is misaligned. This is a recurring problem at the site where castings are purchased from outside. Castings shrink and may warp slightly as they cool and solidify, depending on their shape. While the machined surfaces can be measured, the often-curved casting surfaces are difficult to measure, leading to the next lot being processed without grasping the location and amount of misalignment. Karmo Casting measures the entire shape, including the casting surface, using two contact-type three-dimensional measuring machines and a non-contact 3D digitizer. In August 2026, a 3D scanner, NIMBLETRACK Gen2, was also introduced. By quantifying the misalignment and reflecting it in the correction of wooden patterns produced in-house and the establishment of machining standards, the entire process from casting to machining and inspection can be consolidated in one factory. The ability to distinguish whether the cause of the misalignment lies in casting or machining within the same company is a significant difference compared to ordering processes separately. We are offering a guidebook summarizing the causes and countermeasures for casting defects for free.

• Contract manufacturing
• Processing Contract

The shape has been determined with parts made by a 3D printer. However, as the number of evaluation units increases, the cost accumulates because each one is produced individually. With resin printed parts, the strength and heat resistance when integrated into the actual machine cannot be verified. This is a common concern we hear in the development field. Since 3D printers do not require molds, the first piece can be produced quickly and cheaply. However, the same effort and cost continue for each subsequent piece. Even when entering a stage where multiple units are needed, continuing to produce with 3D printing becomes more expensive than using a mold-making method. Karmo Casting replaces the shape of 3D printed parts with aluminum sand castings. Since we handle everything in-house from mold making to casting, machining, and inspection with three-dimensional measuring machines, we can provide parts made from materials close to the actual production. Transitioning from 3D printing allows for cost savings when producing two or more units, and we can respond in as little as one week. If you want to change the shape during the evaluation process, we can modify the molds made in-house, allowing for design changes to proceed with the same sense as with 3D printing. We are offering a free collection of VA/VE case studies summarizing examples of cost reduction through method conversion.

• Contract manufacturing
• Processing Contract

I want to create water channels inside the body. However, the shape of the core is complex, and there are concerns about the flow of molten metal. Additionally, the processing tolerances are strict, making it inherently a difficult product, and even when searching separately for casting and machining, it is hard to find someone willing to take on the job. Are you facing issues with such components? Castings that incorporate water channels are challenging because the production of cores that shape narrow, curved passages is difficult, and measures to ensure the flow of molten metal reaches even the thin parts during casting are essential. Furthermore, to achieve strict tolerances, precision management that considers machining standards from the casting stage is necessary. When casting and machining are separated, this management can be interrupted between processes. Karmo Casting is a foundry manufacturer that handles everything in-house, from the design and production of wooden patterns and cores to casting, machining, and inspection. We confirm the flow of molten metal and solidification in advance through casting simulations, finalize multiple surfaces with a 5-axis machining center, and verify dimensions with a three-dimensional measuring machine before shipping. This product, which has become one of the most challenging for us, was managed for precision consistently from casting to machining. We are offering a free guidebook on casting defect countermeasures and a collection of VA/VE case studies. Please download them from the link below.

• Contract manufacturing
• Processing Contract

We received an inquiry regarding aluminum castings that were being cast by another company, where casting defects appeared on the machined surfaces, and leaks could not be stopped during the airtightness test. The defect rate reached 80%, and they were casting multiple times the necessary quantity to secure good products. In castings with internal passages, the cores that shape the passages can sometimes cause casting defects. Gases generated from the cores due to the heat of the molten metal can become trapped inside the casting, appearing as holes on the machined surfaces and creating pathways for leaks. Simply changing the casting conditions will not stop this type of defect. Karmo Casting reviewed the drawings and defective products, narrowing down the causes to the cores and the surface of the molds. We proposed changing to core sand that suppresses gas generation and improved the coating applied to the surface of the molds. We conducted everything in-house, from casting to machining and inspection using a three-dimensional measuring machine, reducing the defect rate from 80% to below 3%. The switch can be made after confirming quality with a single prototype, and factory tours before the contract are also possible. We are offering a free guidebook summarizing the causes and countermeasures for casting defects such as casting defects, poor flow, and cracking. Please download it from the link below.

• Contract manufacturing
• Processing Contract

We are machining parts made of bronze, brass, and aluminum bronze from round bars and thick plates. Every time we arrange materials, we are concerned about the high unit price, and much of what we cut ends up as chips. The ratio of waste increases with hollow sections and shapes with steps. Copper alloys are inherently expensive compared to aluminum and iron, so the amount removed from the material directly reflects the cost. In machining, where we prepare a material that is larger than the finished shape, more complex parts result in a greater amount of purchased material being wasted. Karmo Casting proposes shapes for sand castings that are close to the finished form based on the drawings of the machined parts. By designing and manufacturing wooden patterns in-house, we can shape hollow sections and steps in advance with castings, thereby reducing the necessary material and the amount to be machined. We accommodate eight material types, including bronze such as CAC403 and CAC406, high-strength brass, and aluminum bronze. Machining and inspection using a three-dimensional measuring machine are also conducted in-house, allowing us to verify the shape with a single prototype before switching. We are offering a free collection of VA/VE case studies, including examples of cost reduction by switching from machining to casting. Please download it from the link below.

• Contract manufacturing
• Processing Contract

The parts are machined from block material, with most of the material turning into chips. There are many pockets and cutouts, and processing one piece can take several hours. As the quantity increases, the material costs and machine operating time become burdensome. Are there any such parts? While machining does not require molds and can be produced quickly, it involves shaping larger materials than the final form, which means that as the complexity of the shape increases, the amount of material removed and the time taken also increase. For parts that are produced in larger quantities, this difference directly translates into cost differences. Karmo Casting proposes sand casting shapes that can be cast close to the final form based on the drawings of machined parts. By designing and manufacturing wooden molds in-house and creating castings that minimize the machining allowance to necessary areas, we reduce the amount of material removed and the processes involved. After casting, we finish multiple surfaces using a 5-axis machining center and verify dimensions with a three-dimensional measuring machine before shipping. The interface for molds, casting, and machining is handled by a single company, allowing for a shape to be confirmed with one prototype before switching. We are offering a free collection of VA/VE case studies, including examples of cost reduction by switching from machining to casting. Please download it from the link below.

• Contract manufacturing
• Processing Contract

During the airtightness test after processing, leaks were found, resulting in the parts that had been carefully machined becoming defective. For industrial machine parts cast by another company, the defect rate reached 70%. We received an inquiry under such circumstances. The cause of the leaks was shrinkage cavities. When the thicker sections solidify last, if the supply of molten metal cannot keep up, cavities remain inside. Even if they are not visible on the casting surface, they appear on the surface when machined, creating a pathway for leaks. Since the cause lies in the arrangement of the risers and gates, simply changing the foundry will not resolve the issue. Karmo Casting reviewed the drawings and defective products, and redesigned the process. We verified the solidification sequence and flow of molten metal in advance through casting simulations, and modified the design to ensure that molten metal reaches the thicker sections. We carried out everything in-house, from the production of wooden patterns to casting, machining, and inspection, reducing the defect rate from 70% to 3%. The switch can be made after confirming quality with a single prototype, and factory tours before the contract are also possible. We are offering a free casting defect countermeasure guidebook summarizing the causes and countermeasures for shrinkage cavities, poor metal flow, and cracking. Please download it from the link below.

• Contract manufacturing
• Processing Contract

There are many parts to be made with sand casting. However, it is not enough quantity to warrant creating a die-casting mold. Are you struggling to decide on a manufacturing method for parts that fall into this intermediate quantity range? With sand casting, a mold is created for each casting, so as the quantity increases, the labor and variability in the molds accumulate. On the other hand, die casting requires dedicated molds and equipment, making it difficult to recover mold costs if the quantity is uncertain. Parts that fall into this intermediate range tend to be more expensive regardless of the method used. The solution for this intermediate range is die-cast molds. Since the same mold is used repeatedly, the shapes are more consistent than with sand casting, making it suitable for parts with larger quantities. Karmo Casting is a foundry manufacturer that handles everything in-house, from mold design and production to casting, machining, and inspection. With five casting processes available, we can choose the appropriate method in-house, using sand casting for prototypes and switching to die casting when quantities are sufficient. After casting, we finish multiple surfaces using a five-axis machining center and verify dimensions with a three-dimensional measuring machine before shipping. We are offering a free collection of VA/VE case studies summarizing examples of weight reduction, cost reduction, and shortened delivery times, as well as a guidebook on casting defect countermeasures. Please download them from the link below.

• Contract manufacturing
• Processing Contract

Parts for industrial machinery, such as housings, brackets, and covers, often require only a few units per model. Due to the costs associated with casting, companies continue to machine from block materials, leading to increased material costs and processing time. Is this situation familiar to you? The reason small quantities do not become castings lies in the assumption that molds and machining are arranged separately. When the ordering sources for molds, casting, and machining are divided, initial costs and the effort of arrangement arise for each project, making machining appear faster and cheaper. Karmo Casting is a foundry manufacturer that handles everything in-house, from the production of wooden and metal molds to casting, machining, and inspection. We design casting shapes that minimize machining allowances and finish multiple surfaces using a 5-axis machining center, reducing the amount and processes of material removed. We have five casting processes from sand molds to metal molds, allowing us to choose the method that fits the quantity and shape. We accept everything from single prototypes to additional production runs for the same model under the same system. We are offering free downloads of case studies on cost reductions achieved by switching from machining to casting, as well as a guidebook on measures against casting defects. Please download from the link below.

• Contract manufacturing
• Processing Contract

Casting goes to the casting manufacturer, and machining goes to the machining manufacturer. Have you ever experienced having to redo a prototype because the dimensions of parts for a semiconductor device arranged separately did not match, without knowing where the cause lies? The cause lies in the fragmentation of the process. The casting side is unaware of the machining standards, and the machining side does not know the individual differences in the castings. Variations in machining allowances and misalignment of internal shapes arise where information is interrupted between processes. The more ordering parties there are, the more the effort and lead time for arrangements accumulate. Karmo Casting is a foundry that handles everything in-house, from the production of wooden and metal molds to casting, machining, and inspection. By deciding on the casting plan with machining standards in mind and organizing the setup with knowledge of the state of the castings, information does not get interrupted between processes. Multi-surface machining is done with a 5-axis machining center to minimize setup times, and dimensions are verified with a three-dimensional measuring machine before shipping. Communication is streamlined through a single point of contact, and we accommodate prototypes starting from just one piece. Factory tours before contract signing are also possible. We are offering a collection of case studies demonstrating weight reduction and cost reduction achieved through integrated production, as well as a guidebook for addressing casting defects, free of charge. Please download them from the link below.

• Contract manufacturing
• Processing Contract

In shipbuilding and marine parts, aluminum alloy castings are often used, but have you ever struggled to find a supplier that can handle everything from wooden pattern design to casting, machining, and pressure testing? When different companies are involved at each stage, it complicates responsibility boundaries for shape changes and defects, as well as delivery schedule adjustments. There are also limited casting manufacturers that can handle both aluminum and copper alloy castings. Karmo Casting is a rare manufacturer in Japan that produces both aluminum and copper castings. They provide a consistent process in-house from wooden pattern design to casting, machining, and pressure testing, and have manufactured many aluminum and copper products that leverage the characteristics of shipbuilding and marine parts. This product is a completed case of a shipbuilding aluminum alloy casting made from AC2A material, consistently finished from wooden pattern design to machining and pressure testing. We are offering a technical document summarizing the break-even analysis by method and the approach for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever struggled to find a supplier that can handle the casting, machining, and pressure testing all at once for parts like copper alloy castings used in ships, where the pressure resistance of thick sections is critical? When casting, machining, and pressure testing are outsourced to different companies, the division of responsibility in the event of defects can become ambiguous. There are also limited foundries that can handle both copper alloys and pressure testing. Karmo Casting is a rare manufacturer in Japan that produces both aluminum and copper castings. We provide a consistent process from casting to machining and pressure testing in-house, with a strong focus on the pressure resistance of thick products. We have a proven track record of manufacturing ship parts for many years and can accommodate a wide range of shapes and materials. This product is a completed case of a ship-use copper alloy casting made from CAC406 material, finished consistently from casting to machining and pressure testing. We are offering a technical document summarizing the break-even points by method and considerations for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Parts for semiconductor manufacturing equipment have high precision requirements, and have you ever experienced being turned down for prototype processing even when bringing in materials from other foundries? Castings have variations in shrinkage and internal stress depending on the material, and knowledge of casting is necessary for estimating processing conditions. The higher the dimensional precision required for parts specific to the semiconductor industry, the more difficult it is for manufacturers specializing in machining to make accurate estimates, often leading to delays. Karmo Foundry is a manufacturer that also casts aluminum castings in-house. With processing conditions estimated based on the trends of shrinkage and distortion of raw materials, along with high-precision processing equipment capable of geometric tolerances of ±0.03, we can handle machining contracts for raw materials intended for semiconductor equipment. We can accommodate a wide range of needs, from single units in the prototype stage to ongoing contracts after transitioning to mass production. This product is a compilation of cases where only machining contracts for parts for semiconductor manufacturing equipment were accepted, as part of our special feature on prototype contract processing. We are offering a technical document summarizing the break-even points by method and considerations for small lot production free of charge. Please download it from the link below.

• Processing Contract
• Contract manufacturing

Do you have experience being turned down by a manufacturer specializing in machining when you wanted to machine cast products from other companies in the prototype stage? Castings have variations in shrinkage and internal stress depending on the material, and knowledge of casting is necessary to estimate machining conditions. Manufacturers that specialize in machining often find this estimation difficult and tend to shy away from it. Karmo Casting is a manufacturer that also casts aluminum castings in-house. We can estimate machining conditions based on the trends of shrinkage and distortion of raw materials, allowing us to accept machining contracts for cast products from other companies. We can accommodate a wide range of needs, from single prototypes to ongoing contracts after transitioning to mass production. This product is a special feature on prototype contract machining, summarizing cases where we only accepted machining for cast products from other companies. We are offering a technical document summarizing the break-even point by method and considerations for small lot production for free. Please download it from the link below.

• Processing Contract
• Contract manufacturing

Have you ever been turned down for the replication or production of substitute parts that only exist in physical form, like products from other companies or discontinued items, because you didn't have the drawings on hand? To replicate parts without drawings, it is necessary to measure the shape of the physical object with high precision and reverse-engineer it into 3D CAD data. If the measurement accuracy is low, it cannot be reflected in the mold design that accounts for shrinkage during casting, resulting in replicas that do not match the dimensions. Karmo Casting measures the physical object with high precision using the latest 3D scanners, including non-contact three-dimensional digitizers, and then converts it into 3D CAD data. We handle everything in-house, from mold design to casting, machining, and inspection. By completing the entire process from measurement to mass production in-house, we can reflect the shrinkage amount in the mold design. This product is an example of reverse engineering where we obtained the shape of another company's product from a state without drawings through 3D scanning and consistently replicated it through casting and machining. We are offering a technical document summarizing the break-even points by method and considerations for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever experienced the difficulty of not knowing whether the cause of defects lies in casting or machining for parts with strict requirements for both casting accuracy and machining accuracy, such as brackets for industrial machinery? When the casting manufacturer and machining manufacturer are separate companies, the machining side ends up individually addressing the dimensional variations of the castings, which takes time for feedback. If mass production begins while the boundary of responsibility for accuracy assurance remains ambiguous, it becomes cumbersome to trace the causes of defects. Karmo Casting handles everything in-house, from the design and production of wooden and metal molds to casting, machining, and inspection. By measuring dimensions both immediately after casting and after machining, we can reflect the trends of variations in the machining conditions, thus guaranteeing both casting accuracy and machining accuracy as a unified whole. By consolidating the point of contact, we can also quickly identify the causes when defects occur. This product is an example of an aluminum sand casting bracket made from AC4B-F material, where we provided consistent support from mold design to machining, including accuracy assurance. We are offering a technical document summarizing the break-even points by method and the approach for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever experienced the difficulty of not knowing whether the cause of defects in parts, such as casings for industrial machinery, lies in casting or machining, especially when both casting precision and machining precision are critical? When the casting manufacturer and the machining manufacturer are separate companies, the machining side ends up individually addressing the dimensional variations of the castings, which can lead to delays in feedback. If mass production begins while the boundary of responsibility for precision assurance remains ambiguous, it complicates the investigation of defect causes. Karmo Casting handles everything in-house, from the design and production of wooden and metal molds to casting, machining, and inspection. By measuring dimensions both immediately after casting and after machining, we can reflect the trends of variations in machining conditions, thereby ensuring both casting precision and machining precision as a unified guarantee. With a single point of contact, the investigation of causes when defects occur is also expedited. This product is an example of an aluminum sand casting casing made from AC4B-F material, which has been consistently handled from mold design to machining, including precision assurance. We are offering a technical document summarizing the break-even analysis by method and considerations for small lot production free of charge. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever experienced air pressure leaks during airtightness tests after mass production of copper alloy castings with thick sections, such as those used in industrial machinery? Thick sections solidify more slowly than thin sections, making them more prone to gas defects and shrinkage cavities (internal voids) during cooling. These issues are often not detectable through visual inspection alone, and it is not uncommon for defects to be identified only after airtightness tests or actual assembly. Karmo Casting analyzes the solidification process and cooling rates in advance using casting simulations to identify areas where gas defects and shrinkage cavities are likely to occur. By reviewing the feeding and cooling plans and managing everything in-house from pattern design to casting, machining, and inspection, we can ensure airtight designs before mass production. This product is an example of a copper alloy casting for industrial machinery made from CAC406 material, consistently finished with measures against gas defects and shrinkage cavities in thick sections. We are offering a technical document summarizing the break-even points by method and considerations for small lot production free of charge. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever experienced difficulty finding a manufacturer for copper alloy castings for shipbuilding parts? This product has narrow internal passages, making it challenging to create cores, and they are prone to breaking or deforming under casting pressure, which increases the difficulty of casting while maintaining the passage shape. Manufacturers that outsource wooden patterns and cores tend to take longer to make shape modifications or reassess core strength. Karmo Casting handles everything in-house, from the design and production of wooden patterns and molds to casting, machining, and inspection. We use casting simulations to check the flow of molten metal and pressure on the cores in advance, allowing us to propose designs that minimize the risk of breakage even with narrow cores. Since we have five casting processes in-house, including those for copper alloys, we can select the optimal method based on material and shape. This product is an example of a shipbuilding copper alloy casting made from CAC406 material, consistently finished from wooden pattern design to machining while maintaining a narrow core (passage) structure. We are offering a technical document summarizing the break-even analysis by method and considerations for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever been turned down for prototyping parts with a wide variety of shapes, such as oil filters for industrial machinery, due to costs associated with wooden molds and setup? Manufacturers that outsource wooden molds often face adjustments with their subcontractors every time there is a shape change or modification during the prototyping stage, leading to increased costs and time. In prototypes where the shape is not finalized in one go, this burden of adjustment becomes particularly significant. Karmo Casting handles everything in-house, from the design and production of wooden molds and metal molds to casting, machining, and inspection. We possess five casting processes in-house: sand molds, self-hardening, alkaline phenolic, cold box, and metal molds, allowing us to respond immediately to shape changes internally. By consolidating points of contact, we can offer short lead times and low costs even for prototypes. This product is an example of an oil filter made from AC4B-F material, handled consistently from wooden mold design to machining, and responding to shape evaluations during the prototyping stage. We are offering a technical document summarizing the break-even point by manufacturing method and considerations for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever missed the timing due to the costs of wooden molds and adjustments with outsourcing when you wanted to produce small quantities of parts like head covers for industrial machinery? Manufacturers that outsource wooden molds often have separate contacts for mold makers and casting or machining manufacturers, which leads to additional adjustment costs and time every time there is a change in shape. In small-lot production, this burden of adjustments can pressure profitability. Karmo Casting handles everything in-house, from the design and production of wooden and metal molds to casting, machining, and inspection. We have five casting processes in-house: sand molds, self-hardening, alkaline phenolic, cold box, and metal molds, allowing us to choose the optimal method based on quantity and shape. By consolidating contacts, we can achieve short lead times and low costs even for small-lot production. This product is an example of a head cover made from AC2A-F material, handled consistently from wooden mold design to machining, accommodating small-lot production. We are offering a technical document summarizing the break-even points by method and considerations for small lot production free of charge. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever experienced being turned down for machining because you brought in castings from another company that couldn't meet the tolerances? The more precise the tolerances required for shapes, such as parts for semiconductor manufacturing equipment, the fewer machining options are available. With castings from other companies, it is difficult to grasp the variations in shrinkage and internal stress for each casting, and know-how is required to machine them while guaranteeing tolerances. If the assessment is incorrect, dimensions may deviate during the machining process. Karmo Casting conducts its own casting, allowing for the estimation of machining conditions based on the tendencies of shrinkage and distortion of the castings. By using a contact-type three-dimensional measuring machine and a non-contact digitizer to check dimensions during and after machining, we can achieve high-precision tolerances even for castings from other companies. This product is an example of finishing a different part for semiconductor manufacturing equipment to meet tolerances using our unique know-how from castings produced by another company. We are offering a technical document summarizing the break-even point by method and considerations for small lot production for free. Please download it from the link below.

• Processing Contract
• Contract manufacturing

Have you ever struggled to find a machining partner for castings produced by other companies? For rough materials that require high precision, such as parts for semiconductor manufacturing equipment, there are limited machining partners that can handle only the downstream processes. Casting manufacturers often prioritize finishing their own cast products, making it difficult to process castings produced by others due to precision assurance issues, leading to procurement challenges. The uncertainty regarding material properties and shrinkage of rough materials also complicates the estimation of machining conditions. Karmo Casting owns machining equipment, including 15 five-axis machining centers, and can accept rough materials from other companies for machining after confirming their material and shape. Since we also conduct our own casting, we can accommodate the estimation of machining conditions considering the shrinkage and distortion of rough materials. This product is an example of parts for semiconductor manufacturing equipment that have been consistently finished from machining to inspection using rough materials cast by other companies. We are offering a technical document summarizing the break-even points by method and considerations for small lot production free of charge. Please download it from the link below.

• Processing Contract
• Contract manufacturing

Have you ever received inquiries about materials with casting characteristics that are difficult, such as AC8B, which has challenges with flow and shrinkage? For parts like pistons, where dimensional accuracy and strength must be balanced, the properties of the material increase the difficulty of casting. AC8B-based alloys containing Si, Ni, and Cu have a low thermal expansion coefficient and excellent high-temperature strength, but they also have low fluidity and significant shrinkage during solidification, leading many manufacturers to postpone mass production. Karmo Casting designs and manufactures wooden and metal molds in-house and possesses five casting processes: sand casting, self-hardening, alkaline phenolic, cold box, and metal mold casting. We propose mass production designs that minimize yield loss, even for materials with challenging characteristics, by confirming solidification and flow in advance through casting simulations. This product is an example of how the casting and machining technology for AC8B pistons developed for compressor parts has been applied to sliding parts and heat-resistant components in other industries, such as automotive and industrial machinery. We offer a technical document summarizing the break-even points by method and considerations for handling difficult-to-cast materials, available for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Due to the use of cores in the shape, casting costs and delivery times have increased, and have you ever considered cost reduction at the timing of mass production? Core structures not only increase mold costs and labor hours but also contribute to lower yields during mass production due to constraints on flow and strength. Karmo Casting designs and manufactures wooden and metal molds in-house, allowing us to provide consistent support from shape modification proposals to mass production transition. We possess five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, enabling us to select the optimal method based on quantity and shape. By confirming solidification and flow in advance through casting simulations, we can minimize the risk of rework even after eliminating cores. We provide comprehensive support for machining, inspection, and surface treatment after casting. This product proposes a shape modification for core elimination, and during the startup phase, we respond with sand casting due to the small quantity. In response to the increased demand accompanying the transition to mass production, we proposed mold creation, achieving cost reduction and lead time shortening. We are offering a technical document summarizing the break-even points by method and considerations for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

After receiving the drawings, have you ever struggled with coordinating delivery times and aligning quality when the orders for wooden patterns, casting, and machining are placed with different suppliers? When different subcontractors are involved at each stage, it can lead to losses in information transfer and response to modifications, and the responsibility for defects can become ambiguous. Karmo Casting designs and manufactures wooden patterns and molds in-house, allowing us to provide a one-stop solution from the moment we receive the drawings to mass production. We possess five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and molds, enabling us to select the optimal method based on quantity and shape. By confirming solidification and flow in advance through casting simulation, we can minimize the risk of rework even for small quantities. We handle everything from machining, inspection, to surface treatment after casting in a fully integrated in-house system. This is a case study of a product completed through our consistent production process, from consultation on the drawings to wooden pattern design, casting, and machining. We are offering a technical document summarizing the break-even points by method and considerations for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever been turned down by a foundry manufacturer for the reason of "only one piece" or "unable to guarantee the system"? One of the major reasons for avoiding small quantities is the significant effort involved in changing setups. Karmo Foundry designs and manufactures wooden and metal molds in-house, allowing us to keep mold costs and lead times down even for small quantities. We have five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, enabling us to select the optimal method based on quantity and shape. By confirming solidification and flow in advance through casting simulations, we can minimize the risk of rework even for small quantities. We provide a comprehensive response, including arrangements for machining, inspection, and surface treatment after casting. This is a case study of a product where there was a request to reduce thickness for weight reduction. We are offering a technical document summarizing the break-even points by method and our approach to small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever been turned down by a foundry manufacturer for the reason of "just one piece" or "just a few pieces"? This happens regularly in the fields of prototyping, maintenance, and custom orders. The reason for avoiding small quantities lies in the costs of molds and setup. Manufacturers that outsource wooden and metal molds cannot lower the initial costs for small projects. Karmo Foundry designs and manufactures wooden and metal molds in-house, allowing us to keep mold costs and delivery times down even for small quantities. We have five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, enabling us to choose the optimal method according to quantity and shape. By using casting simulations to confirm solidification and flow in advance, we can minimize the risk of rework even for small quantities. We provide a consistent response from machining, inspection, to surface treatment after casting. We accept everything from single prototypes to mass production under the same system. We can also replicate parts that only exist in physical form without drawings. We offer a technical document summarizing the break-even points by method and our approach to small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever encountered any issues in the past during the prototype consideration before mass production? Our company has extensive experience from prototyping to mass production, and we propose optimal materials and methods to our customers by identifying concerns from drawings and data. Karmo Casting designs and manufactures wooden and metal molds in-house, allowing us to have a wealth of experience from prototype molds to mass production molds, and we support our customers in product development. We possess five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, and we select the optimal method according to quantity and shape. By using casting simulation to verify solidification and flow in advance, we can minimize the risk of rework even for small quantities. We provide consistent support from machining, inspection, to surface treatment after casting. Due to the risk of distortion with larger product sizes and concerns during mass production from the prototype stage, we proposed shape modifications to prepare for these risks. We offer a technical document summarizing the break-even point by method and considerations for small lot production free of charge. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever encountered any issues in the past during the prototype consideration before mass production? Our company has extensive experience from prototyping to mass production, and we propose optimal materials and methods to our customers by identifying concerns from drawings and data. Karmo Casting designs and manufactures wooden and metal molds in-house, which allows us to have a wealth of experience from prototype molds to mass production molds, and we support our customers in product development. We possess five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, and we select the optimal method according to quantity and shape. By confirming solidification and flow in advance through casting simulation, we can minimize the risk of rework even for small quantities. We provide consistent support from machining, inspection, to surface treatment after casting. Although there were special requirements for casting tolerances relative to product size, which demanded high precision, our sand castings can meet these high precision requirements, allowing us to fulfill our customers' requests. We offer a free technical document summarizing the break-even analysis by method and considerations for small lot production. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever been turned down by a foundry manufacturer for the reason that you only need about 30 pieces a year and a lot of about 10 pieces? The procurement of small quantities is a common issue faced by customers when selecting suppliers. The reason for avoiding small quantities lies in the costs of molds and setup. Manufacturers that outsource wooden or metal molds cannot lower the initial costs for small projects. Karmo Foundry designs and manufactures wooden and metal molds in-house, allowing us to keep mold costs and lead times down even for small quantities. We have five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, enabling us to choose the optimal method based on quantity and shape. By using casting simulations to verify solidification and flow in advance, we can minimize the risk of rework even for small quantities. We provide a consistent response from machining and inspection to surface treatment after casting. Although there were special requirements for casting tolerances relative to product size, and high precision was demanded, our sand castings can meet these precision requirements, allowing us to fulfill customer requests. We are offering a technical document summarizing the break-even points by method and considerations for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever been turned down for aluminum machined parts, whether it's just one piece or a few, due to quantity? Moreover, there are only a limited number of manufacturers capable of processing parts over 1,000mm. Karmo Casting owns two large 5-axis machining centers (one of which has a pallet changer) and two gantry machining centers, allowing us to accommodate machining from just one piece. We also design and manufacture our own machining jigs in-house, ensuring stable precision with geometric tolerances of ±0.03 by carefully crafting the gripping methods. Furthermore, while we are a casting manufacturer, we have extensive machining know-how and a proven track record of total cutting processed products, enabling us to propose the optimal machining methods simply based on the data you provide.

• Processing Contract
• Contract manufacturing

Have you ever experienced being turned down for aluminum machined parts, whether it's "just one" or "only a few," due to quantity? This happens regularly in the procurement of prototypes, jigs, and maintenance parts. The reason for avoiding small quantities lies in the setup. The time required for program creation and jig preparation cannot be easily justified by the quantity. Karmo Casting owns 15 five-axis machining centers (6 of which are equipped with pallet changers) and 2 gantry machining centers, allowing us to handle machining from a single piece. We also design and manufacture processing jigs in-house, ensuring stable precision with geometric tolerances of ±0.03 from the gripping method. Parts that exist only as physical items without drawings can also be replicated using a non-contact 3D scanner. Furthermore, we are a casting manufacturer. When the quantity increases to the point where material costs and machining time no longer align, we can propose a method transition to casting. The benchmarks are reduced lead times for orders of three or more and cost reductions for five or more. Starting with machining and transitioning to casting for mass production can be completed by a single company. We offer a free collection of case studies summarizing the criteria for method transition and cost comparisons.

• Processing Contract
• Contract manufacturing

Here is an example of long aluminum parts mounted on railway vehicles. Long aluminum parts mounted on railway vehicles can easily warp or bend due to even slight thermal stress during processing. Our company addresses this challenge with an integrated in-house production system centered around precision sand casting and five-axis machining centers. We optimize materials and propose shapes to ensure that the parts are shaped to avoid bending during the casting stage before machining. Design, manufacturing, and quality assurance collaborate on the same floor to share issues in real-time. 【Case Overview】 ■ Size: L600×W400×H100mm ■ Material: AC4CH-T6 ■ Industry: Railway ■ Process: Casting → Heat Treatment → Machining → Inspection ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing
• Processing Contract

We would like to introduce a case where we received a request for the production of aerospace-related parts using block material provided by a customer from the aviation and space industry. The part we are introducing this time is an aluminum component processed from the block material supplied by the customer, using full cutting. Due to its thin-walled shape with a thickness of 3mm and being a small component, there were challenges such as warping and vibration during processing. Our company designed dedicated jigs and optimized cutting conditions to achieve stable quality while minimizing deformation. Additionally, we have obtained JIS Q 9100 certification, which allows us to meet strict quality requirements. 【Case Overview】 ■ Size: L300×W300×H200mm ■ Material: A5052 ■ Industry: Aviation and Space ■ Process: Material supply → Machining → Inspection ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For more details, please download the PDF or feel free to contact us.

• Processing Contract
• Contract manufacturing

Are you struggling with delivery delays due to re-manufacturing caused by pressure leakage from quality issues with your current manufacturer, which are discovered before the final process? We often receive inquiries such as, "I want to produce with stable quality and delivery, but the current manufacturer only addresses the casting process, and quality improvements that include pressure defects after machining are not progressing." At Karmo Foundry, we have five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and die casting, allowing us to select the optimal method according to quantity, shape, and quality requirements. Moreover, by handling everything from casting to machining and pressure testing in a consistent production process, we can proceed with manufacturing while confirming quality up to the final stage. Additionally, we utilize casting simulations to check the flow of molten metal and solidification conditions in advance, aiming to reduce the risk of casting defects and re-manufacturing from the prototype stage. If you are facing quality issues such as pressure leakage or delivery delays due to re-manufacturing, please feel free to consult us. We also provide technical materials summarizing our know-how on casting defects and quality improvement for free. Please download them from the link below.

• Contract manufacturing
• Processing Contract

Are you facing increased labor hours and delays in delivery due to quality issues with your current manufacturer, resulting in rework and remanufacturing? We often receive inquiries from clients who want to produce with stable quality and delivery times, but find it difficult to achieve improvements with their current manufacturer. On the other hand, changing suppliers can lead to changes in processes, so we also hear voices saying, 'I want to change, but the costs of molds and the setup time are obstacles that make it hard to take the plunge.' Additionally, we possess five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and die casting, allowing us to select the optimal method based on quantity, shape, and quality requirements. Furthermore, by utilizing casting simulations to confirm the flow of molten metal and solidification conditions in advance, we aim to reduce the risks of casting defects and rework from the prototype stage. We can consistently handle everything from machining, inspection, to surface treatment after casting, which helps alleviate the burden when changing suppliers. If you are struggling with quality improvements, delivery delays, or switching from your current supplier, please feel free to consult with us. We also offer free technical materials summarizing our know-how on casting defects and quality improvements. Please download them from the link below.

• Contract manufacturing
• Processing Contract

Have you ever been turned down by a foundry because you needed around 30 pieces a year with a lot size of about 10? The procurement of small quantities is a common issue faced by customers when selecting suppliers. The reason for avoiding small quantities lies in the costs of molds and setup. Manufacturers that outsource wooden and metal molds cannot reduce the initial costs for small projects. Karmo Casting designs and manufactures wooden and metal molds in-house, allowing us to keep mold costs and lead times low even for small quantities. We possess five casting processes: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, enabling us to choose the optimal method based on quantity and shape. By using casting simulations to verify solidification and flow in advance, we can minimize the risk of rework even for small quantities. We provide a consistent response from machining, inspection, to surface treatment after casting. We accept everything from a single prototype to mass production under the same system. We can also replicate parts that only exist as physical samples without drawings. We offer a technical document summarizing the break-even analysis by method and considerations for small lot production, available for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever been turned down by a foundry manufacturer for the reason of "just one piece" or "just a few pieces"? The procurement of small quantities of mass-produced items is a common issue faced by customers when selecting suppliers. The reasons for avoiding small quantities are related to mold costs and setup. Manufacturers that outsource wooden or metal molds cannot lower the initial costs for small projects. Karmo Foundry designs and manufactures wooden and metal molds in-house, allowing us to keep mold costs and delivery times down even for small quantities. We have five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, enabling us to choose the optimal method based on quantity and shape. By using casting simulations to verify solidification and flow in advance, we can minimize the risk of rework even for small quantities. We provide a consistent response from machining, inspection, to surface treatment after casting. We accept everything from prototype production of one piece to mass production under the same system. We can also replicate parts for which we only have the physical item and no drawings. We offer a technical document summarizing the break-even points by method and considerations for small lot production for free. Please download it from the link below.

• Contract manufacturing
• Processing Contract

Have you ever been turned down by a foundry manufacturer for the reason of "just one piece" or "just a few pieces"? This happens regularly in the fields of prototyping, maintenance, and custom orders. The reason for avoiding small quantities lies in the costs of molds and setup. Manufacturers that outsource wooden and metal molds cannot lower the initial costs for small projects. Karmo Foundry designs and manufactures wooden and metal molds in-house, allowing us to keep mold costs and lead times down even for small quantities. We have five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and metal molds, enabling us to choose the optimal method based on quantity and shape. By using casting simulations to check solidification and flow in advance, we can minimize the risk of rework even for small quantities. We provide a consistent response from machining, inspection, to surface treatment after casting. We accept everything from a single prototype to mass production under the same system. We can also replicate parts that only exist in physical form without drawings. We offer free technical materials summarizing the break-even points by method and considerations for small lot production. Please download them from the link below.

• Contract manufacturing
• Processing Contract

Since it was a small quantity for a prototype, machining from block material resulted in most of the material becoming waste, and the processing time directly translates to costs. The more the quantity increases, the more disadvantageous it becomes, yet there are many parts that remain as machined due to precision reasons. Many of the reasons for machining stem from the premise of 'small quantities' and 'wanting to verify through prototypes.' However, if mass-produced items can be processed in-house after casting, then simply machining the necessary surfaces can maintain precision while reducing costs. Our company is a casting manufacturer and owns 15 five-axis machining centers, allowing us to provide a consistent response from casting to finishing. Based on total cutting data and considering the characteristics of casting, we can set processing costs while compressing material costs and processing time, all while maintaining precision equivalent to machining. We also offer process support from the drawing stage. 【Break-even point】Shortened delivery for 3 or more pieces / Cost reduction for 5 or more pieces 【Precision】Numerous achievements with geometric tolerances of ±0.03, guaranteed by two three-dimensional measuring machines 【Effect】There are cases where multiple parts were integrated into a single casting, reducing part costs and assembly labor. We are offering a free collection of VA/VE case studies summarizing the criteria for process conversion and cost comparisons.

• Contract manufacturing
• Processing Contract

At Karmo Casting, which operates aluminum casting and machining solutions, we have achieved quality improvement, cost reduction, shortened delivery times, and weight reduction through VA/VE proposals based on years of accumulated technology and achievements in industries such as transportation, including automotive and aerospace, as well as in the semiconductor and telecommunications equipment sectors. This document summarizes such case studies to provide hints for designers and developers considering product improvements. Please feel free to download it. [Contents] ■ About aluminum casting ■ Quality improvement case studies ■ Cost reduction case studies ■ Delivery time reduction case studies ■ Weight reduction case studies ■ About Karmo Casting Co., Ltd. *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing
• Processing Contract

At Karmo Casting, which operates aluminum casting and machining solutions, we have established a system to prevent casting defects and have resolved our customers' quality challenges. This document summarizes the causes and countermeasures for casting defects, as well as actual case studies, aimed at procurement and purchasing personnel who are struggling with the quality of aluminum castings. Please feel free to download it. [Contents (partial)] ■ About casting defects ■ Causes/countermeasures and case studies for shrinkage cavities ■ Causes/countermeasures and case studies for gas defects (blowholes, pinholes, and blowouts) ■ Causes/countermeasures and case studies for cracks ■ Causes/countermeasures and case studies for poor metal flow, metal wrinkles, and metal boundaries *For more details, please download the PDF or feel free to contact us.

• aluminum
• Casting Machine
• Contract manufacturing

The defect rate of castings requested from other companies is not decreasing. The defects in mass-produced items are not stopping. Even when we request countermeasures, we receive the response, 'It's difficult because it's casting'—this is the most common consultation received from the procurement and quality assurance departments. Casting defects cannot be resolved without identifying the causes in the casting plan, sand, melting conditions, mold coating, and temperature. Factories that only have a single casting process cannot perform this differentiation. Our company has five casting processes in-house: sand mold, self-hardening, alkaline phenolic, cold box, and metal molds. Based on numerous casting simulation results, we predict the location of defects at the design stage. Since both wooden and metal molds are produced in-house, we can handle everything from plan changes to remanufacturing internally. [Results Achieved] Over 100 problem-solving cases / 100 companies and 500 items in the last 5 years ■ Major machinery manufacturer: defect rate over 80% → less than 5% ■ Marine valve case: shrinkage defect 70% → about 5% ■ Resolved pouring defects in communication equipment frames, pinholes in industrial machinery frames, and inclusions and casting surface defects in generator control cases. We are offering a free copy of the 'Aluminum Casting Defect Countermeasure Guidebook,' which summarizes countermeasures by cause.

• Contract manufacturing
• Processing Contract