カルモ鋳工 Product Lineup

We would like to introduce a case study that addresses issues such as blade angle, shrinkage defects, and mold misalignment in engine parts. There are 11 sand molds placed inside the blades, but they are set in one go using a dedicated jig, ensuring that the blade angles do not shift. The aluminum pouring process is simulated and analyzed to standardize the quantity and speed of pouring using a wooden pattern, maintaining the same conditions each time. Additionally, because the mold alignment is precise, there is very little burr formation, significantly reducing the time required for manual finishing. 【Case Overview】 ■ Size: L600×W400×H250mm ■ Material: AC4B-F ■ Industry: Generator ■ Product Name: Generator-related parts ■ Process: Cold core → Flask core → Self-hardening → Finishing → Heat treatment → Measurement → Inspection ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For detailed information about the case, please refer to the related links. For more information, feel free to download the PDF or contact us.

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Here is an example of aluminum castings used as doors for control equipment. The challenge was "tapping hole processing and groove processing in thin-walled structures." Due to the limited wall thickness for tapping hole processing, we optimized the depth of the pilot hole and the treatment of the bottom end of the tap to prevent breakthrough. For groove processing, it was necessary to create narrow grooves in the thin-walled sections, taking into account the balance between tool rigidity and cutting resistance. We adjusted the tool rotation speed and feed conditions to minimize deformation and burr formation. 【Case Overview】 ■ Size: L500×W400×H200mm ■ Material: AC4B-F ■ Industry: Semiconductor and Communication Equipment ■ Product Name: Control Equipment Parts ■ Process: Self-hardening → Finishing → Processing → Inspection ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For detailed information about the case, please refer to the related links. For more information, feel free to download the PDF or contact us.

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Here is an example of a product primarily used as a railway component. This product's casting utilizes six cores, resulting in a complex and intricate internal shape. Additionally, it has multiple holes and features both thick and thin areas, making it prone to issues like shrinkage cavities. However, by carefully refining the design, we have been able to resolve these problems. 【Case Overview】 ■ Size: L100×W100×H50mm ■ Material: AC4CH-T6 ■ Industry: Railway ■ Product Name: Railway Component ■ Process: Core → Self-hardening → Finishing → Heat Treatment → Inspection ■ Delivery Time: 2 weeks ■ Lot Size: Starting from 1 piece *For more detailed information about this case, please refer to the related links. For further details, feel free to download the PDF or contact us.

• Contract manufacturing
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Our company manufactures wooden molds not from wood, but by machining high-performance resin materials. Resin molds have less deformation than wood and can produce highly accurate casting molds. They are less susceptible to moisture and aging, making them suitable for long-term storage. Additionally, they have excellent machinability, allowing for high-quality finishes on complex shapes. Furthermore, our high-speed machining is overwhelmingly faster than 3D printing. We have received positive feedback from many customers for both shortened delivery times and cost reductions. 【Case Overview】 ■ Size: L320×W220×H180mm ■ Material: Sanmodule ■ Industry: Other ■ Product Name: Wooden Mold ■ Process: CAM Data Creation → Machining → Inspection ■ Delivery Time: 4 days ■ Lot Size: From 1 piece *For detailed information about the case, please refer to the related link. For more details, feel free to download the PDF or contact us.

• Contract manufacturing
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Here is an example of copper alloy components used in power-related equipment. At first glance, the shape appears simple, but in actual manufacturing, there are challenges such as the tendency for gas defects and shrinkage specific to copper alloys, the risk of internal defects due to thick-walled shapes, and the necessity of optimizing casting conditions to stabilize quality. Our company addresses these issues by optimizing cooling conditions and employing flow analysis for design, which helps suppress defects. We achieve stable quality through management and finishing by skilled craftsmen. 【Case Overview】 ■ Size: L200×W150×H80mm ■ Material: AC4CH-T6 ■ Industry: Railway ■ Product Name: Railway Component ■ Process: Core → Mold → Melting → Finishing → Heat Treatment → Inspection ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For detailed information about the case, please refer to the related links. For more information, feel free to download the PDF or contact us.

• Contract manufacturing
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Here is an example of aluminum cast parts used in ships. Due to the small and precise nature of the products, even slight molding defects can lead to issues, requiring advanced casting technology and precise mold design. Our company has optimized the parting line (mold division) and significantly reduced the labor required for wooden pattern production. By using multi-cavity molds, we have achieved stable quality even in large lots. 【Case Overview】 ■ Size: L500×W500×H300mm ■ Material: AC2A-T6 ■ Industry: Marine ■ Product Name: Ship Parts ■ Process: Molding → Melting → Finishing → Heat Treatment → Inspection ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For more detailed information about the case, please refer to the related links. For more details, feel free to download the PDF or contact us.

• Contract manufacturing
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Here is an example of aluminum cast parts used in agricultural machinery. These are critical components that require high precision and durability to function reliably even in harsh environments. During the finishing process, excess material is carefully removed while maintaining the curvature of the surface. Even slight distortions or deformations can lead to defects, so skilled technicians combine manual work with machining to achieve high-precision finishes. 【Case Overview】 ■ Size: L200×W100×H100mm ■ Material: AC4A-T6 ■ Industry: Agricultural Machinery ■ Product Name: Agricultural Equipment Parts ■ Process: Molding Alkali → Finishing → Heat Treatment → Machining → Maintenance → Measurement Inspection ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For more detailed information about the case, please refer to the related links. For further details, feel free to download the PDF or contact us.

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Here is an example of aluminum casting parts for automobiles. Automotive parts require safety and durability, so high precision and stable quality are essential. This product has a very small R shape (curve), making it difficult to mold, and filling the sand mold is challenging with just conventional machine molding. Our company provides high-quality cast products consistently through a hybrid process of machining and manual work. 【Case Overview】 ■ Size: L450×W320×H290mm ■ Material: AC4B-T6 ■ Industry: Automotive ■ Product Name: Automotive Parts ■ Process: Cold → Green Sand → Finishing → Heat Treatment ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For more details about the case, you can view it through the related link. For more information, please download the PDF or feel free to contact us.

• Contract manufacturing
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Here is an example of copper alloy cast parts used in power-related equipment. Power components require "safety, reliability, and durability," making high casting technology and quality control essential. Our company achieves stable fillability and high quality through appropriate runner design using flow simulation and thorough management of casting conditions (temperature, pressure, speed). 【Case Overview】 ■ Size: L200×W180×H80mm ■ Material: CAC406 ■ Industry: Others ■ Product Name: Brake Parts ■ Process: Sand Mold → Melting → Finishing → Inspection ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For detailed information about the case, please refer to the related links. For more information, feel free to download the PDF or contact us.

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Here is an example of aluminum cast parts used in industrial machinery. Due to its thin wall thickness and small corner radii, this product requires high molding technology and stable quality control. To accurately reproduce the rib shape, special attention is paid to the sand filling and extraction processes during molding. In the finishing process, precise manual work is carried out to prevent excessive polishing that could deform the thin-walled shape. 【Case Overview】 ■ Size: L150×W120×H100mm ■ Material: AC4CH-T6 ■ Industry: Railway ■ Product Name: Railway Vehicle Parts ■ Process: Molding self-hardening → Melting → Finishing → Heat Treatment ■ Delivery Time: 2 weeks ■ Lot Size: From 1 piece *For more detailed information about the case, please refer to the related links. For more details, feel free to download the PDF or contact us.

• Contract manufacturing
• Processing Contract

At Karmo Casting Co., Ltd., we engage in aluminum processing, aluminum casting, and the casting of copper alloys other than aluminum. We also accommodate small lots, including the creation of prototypes and wooden and metal molds, so please feel free to consult us if you have any questions regarding aluminum alloy cutting, machining, or casting. 【Business Activities】 ○ Manufacturing of non-ferrous metal castings (copper alloys, aluminum alloys) ○ Machining ○ Production of wooden and metal molds *For more details, please request our materials or view the PDF data available for download.

• Processing Contract
• Contract manufacturing