We will manufacture one piece or just a few pieces of castings that were declined due to quantity. We have a track record of over 500 prototypes per year and can ship in as little as two weeks.
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.
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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】500mm×3500mm×150mm 【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 Process】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 tolerance 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 keep initial costs low even for small quantities. Since costs vary depending on the manufacturing method, we will also suggest transitioning from machining to 3D printing. (For reference: transitioning from machining requires a minimum of 5 pieces, while transitioning from 3D printing requires a minimum of 2 pieces for cost reduction.)
Price range
P2
Delivery Time
※Prototype shipping takes a minimum of 3 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
【Industries Served】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 quantities) ■ Aluminum parts for agricultural machinery (AC4CH-T6 / High precision finishing) ■ Copper alloy castings for power equipment (CAC406, AC4CH-F, etc. / Thin-walled, internal passages, uneven thickness countermeasures) ■ Bases and pedestals for semiconductor manufacturing equipment (AC4CH-T6) ■ Motor housings for automotive EVs (AC4B-T6, A5052) ■ Resin wood patterns for sand casting (Delivery time 7 days / From 1 type) 【Used in Such Situations】 ・Only a few pieces needed for prototype evaluation ・Manufacturing single parts for discontinued product repair ・Shape evaluation before manufacturing die-casting molds ・Replication of parts with only the actual item available, no drawings 【Achievement Scale】Over 500 prototype and development achievements annually. 200 companies and 5,000 items 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.
