The thickness of the meat is less than 3mm. We propose thin-walled cast pipes that achieve weight reduction. We can produce castings that were declined due to precision issues, starting from just one piece.
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.
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basic information
【Lot Availability】From 1 piece 【Casting Size】50mm square to 1,000mm square / Minimum thickness 2mm (local)・3mm (overall) 【Product Size】350mm×350mm×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 Processes】In-house capabilities for 5 methods: sand casting / self-hardening / alkaline phenolic / cold box / mold 【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 give you a free estimate. We can accommodate production starting from one piece, and by manufacturing molds in-house, we can reduce initial costs 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 size, high precision, mass production) ■ Aluminum parts for agricultural machinery (AC4CH-T6 / High precision finish) ■ Copper alloy castings for power equipment (CAC406, AC4CH-F, etc. / Thin-walled, internal passages, thickness variation measures) ■ 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 items for discontinued product repair parts ・Shape evaluation before manufacturing die-casting molds ・Replication of parts that only exist in physical form without 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.
