Improvement in both cost and quality [Changing from cutting & sand casting to digital casting]
There are no drawings for the parts, and the processing company has gone out of business... If you are having trouble with metal parts, please consider "Digital Cast," a mold-less casting solution.
The image shows an example of a part used in the manufacturing of an elephant trunk (the handle and tip of a rickshaw). The previous material was brass, and it was manufactured through cutting, but it seems the processing company went out of business. After that, it was produced once using sand casting, but it was more expensive and had many defects compared to cutting, which was a problem. Therefore, we proposed digital casting, which can accommodate small lots, and we were able to improve both cost and quality. 【What is Digital Casting?】 A method of producing metal products by creating a resin model with a 3D printer and using it as a prototype, following a process similar to lost-wax precision casting. Castings can be produced in as little as one week, starting from just one piece. We offer proposals that are beneficial even for development and prototyping. If you have parts under consideration for weight reduction or shape changes, please feel free to consult with us. 【Three Features of Digital Casting】 - Shortest delivery time of one week (usually two weeks) - No mold cost - Production possible from a minimum of one piece
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basic information
Traditional methods Cutting processing and sand casting Industry: Tourism Material: SCS13
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Applications/Examples of results
【Examples】 Industrial machinery, semiconductor parts, golf club heads, turbochargers, prototype verification of complex shapes, strength verification of cast products, prototype verification with material changes, original parts manufacturing 【Example Details】 ■Cost Reduction of 80% GG Manifold (Aerospace Component) Two parts were manufactured through machining and then welded together. Due to the use of special materials, they were sourced from overseas processing companies, leading to increased costs. This was resolved with digital casting. The wide range of compatible materials and the integration of parts significantly reduced costs and improved quality through enhanced strength. Material: Inconel 625, Conventional Method: Machining + Welding ■Short Delivery Time Turbine Impeller Parts (Industrial Turbine) For large parts with a diameter of 380 mm, traditional methods required 1 to 2 months for mold production. However, with the digital casting method, cast products can be produced without molds, allowing for significant improvements in delivery times. It can also accommodate special materials such as heat-resistant steel and duralumin. Material: SCS13 ■Prototype Verification Vehicle Development Prototypes (Next-Generation Mobility) The initial costs associated with mold production and quality concerns after mold creation were resolved with digital casting. Verification of cast products was conducted without molds, alleviating quality concerns. Material: FCD
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Company information
With a posture of "just half a step" without complacency, we have cultivated "lost wax precision casting" over many years. Utilizing 3D printing technology, we offer next-generation precision casting technology called "Digital Cast." We obtained a U.S. patent for "MIM (Metal Injection Molding)" in 1991. We provide optimal proposals using various technologies and thoroughly support our customers' manufacturing! We specialize in complex three-dimensional shapes in small lots of various types and carry out everything from mold making to casting, machining, and simple assembly in an integrated in-house system. We supply products to various industries, including medical devices, semiconductors, machine tools, and aerospace. "Just make it, from one piece." We can propose a wide range of manufacturing methods from prototype production of one piece to mass production. We also enable time savings in searching for various suppliers and considering consultation destinations, becoming a true total cost reduction partner by proposing reductions in management costs related to consideration time and product costs. More than half a century ago, Castem began its casting business by handcrafting machine tools. Today, we have become a leading company in Japan for manufacturing general industrial components using lost wax casting and are also engaged in the production of micro lenses and micro needles using the world's highest precision 3D light shaping technology.