We are struggling with casting defects at our current manufacturer... Our company has a wealth of case studies that address issues with casting defects.
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.
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basic information
【Supported Lot】From 1 piece 【Casting Size】50mm square to 1,000mm square / Minimum thickness 2mm (local)・3mm (overall) 【Product Size】350mm square 【Supported Materials】 - Aluminum Alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B (10 types) - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 (8 types) - Heat Treatment: T6 and others available 【Casting Processes】In-house capabilities for 5 methods: sand mold / self-hardening / alkaline phenol / cold box / die 【Machining】15 units of 5-axis machining centers, 2 gantry-type MCs, 3 vertical MCs, 2 NC lathes / Numerous achievements with geometric tolerances of ±0.03 【Inspection】2 contact-type 3D measuring machines, 2 non-contact 3D digitizers (deviation 30-80μ) 【Surface Treatment】Arrangements for plating, painting, anodizing, and impregnation (RoHS and REACH compliant) 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2
Price information
If you provide us with drawings, sample products, or 3D models, we will offer a free estimate. We can accommodate production starting from one piece, and by manufacturing wooden molds and metal molds in-house, we can reduce initial costs even for small quantities. Since costs vary depending on the manufacturing method, we will also propose transitioning from machining to 3D printing. (For reference: transitioning from machining requires a minimum of 5 pieces, and transitioning from 3D printing requires a minimum of 2 pieces for cost reduction.)
Price range
P2
Delivery Time
※The prototype will be shipped in as little as 2 weeks. It may vary depending on the shape, quantity, and whether post-processing is required, so please consult us if you are in a hurry.
Applications/Examples of results
【Applicable Industries】Automotive・CASE / Railways / Aerospace / Marine / Semiconductors・Communication Equipment / Robotics / Machine Tools / Agricultural Machinery / Power・Energy 【Delivery Achievements】 ■ Cylinder cases for railway vehicles (AC4CH-T6 / Complex shapes with more than 6 cores / Delivery time 3 weeks / From 1 piece) ■ Aluminum parts for ships (AC2A-F / Small, high precision, large quantity) ■ Aluminum parts for agricultural machinery (AC4CH-T6 / High precision finish) ■ Copper alloy castings for power equipment (CAC406, AC4CH-F, etc. / Thin-walled, internal passages, uneven thickness measures) ■ Bases and pedestals for semiconductor manufacturing equipment (AC4CH-T6) ■ Motor housings for automotive EVs (AC4B-T6, A5052) ■ Resin wooden patterns for sand casting (Delivery time 7 days / From 1 type) 【Used in Such Situations】 ・Only a few pieces needed for prototype evaluation ・Single production of repair parts for discontinued products ・Shape evaluation before manufacturing die-cast molds ・Replication of parts with only the physical object available, no drawings 【Achievement Scale】Over 500 prototype and development achievements annually. 5,000 items from 200 companies in the last 5 years.
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Company information
At Karmo Casting Co., Ltd., we engage in aluminum processing, aluminum casting, and the casting of copper alloys other than aluminum. Manufacturing has continuously supported the backbone of Japanese industry. At Karmo Casting, we have maintained that spirit and pride, dedicating ourselves to pioneering initiatives in the industry since our founding. Our primary goal is to build partnerships with our customers. To achieve this, we believe it is essential to flexibly adapt to changes in the times and realize all kinds of needs. Our relentless pursuit of technical expertise, responsiveness, quality, and speed reflects this attitude. While sensitively and swiftly understanding our customers' thoughts, Karmo Casting will continue to accumulate tireless efforts and changes as a manufacturing company that is chosen and needed by our customers.
![[ESG・CO2 Reduction] Environmentally Friendly ECO Aluminum Plates, Round Bars, and Recycled Materials](https://image.mono.ipros.com/public/product/image/6636/IPROS14018363916533949281.jpg?w=280&h=280)
