Small lot production of castings | Proposal for integrated production including processing
AC4CH-T6
From receiving the drawings to the completion of mold making, casting, and machining, we handle the entire process in-house. We can produce from a single piece and ship in as little as two weeks.
After receiving the drawings, have you ever struggled with coordinating delivery times and aligning quality when the orders for wooden patterns, casting, and machining are placed with different suppliers? When different subcontractors are involved at each stage, it can lead to losses in information transfer and response to modifications, and the responsibility for defects can become ambiguous. Karmo Casting designs and manufactures wooden patterns and molds in-house, allowing us to provide a one-stop solution from the moment we receive the drawings to mass production. We possess five casting processes in-house: sand casting, self-hardening, alkaline phenolic, cold box, and molds, enabling us to select the optimal method based on quantity and shape. By confirming solidification and flow in advance through casting simulation, we can minimize the risk of rework even for small quantities. We handle everything from machining, inspection, to surface treatment after casting in a fully integrated in-house system. This is a case study of a product completed through our consistent production process, from consultation on the drawings to wooden pattern design, casting, and machining. We are offering a technical document summarizing the break-even points by method and considerations for small lot production for free. Please download it from the link below.
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basic information
【Process】Receiving drawings → Design and production of wooden patterns → Casting → Machining → Inspection → Shipping with an in-house integrated system 【Lot Size】From 1 piece 【Casting Size】50mm square to 1,000mm square / Minimum thickness 2mm (local)・3mm (overall) 【Product Size】350mm × 350mm × 100mm 【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 possession of 5 methods: sand casting / self-hardening / alkaline phenolic / cold box / metal 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. Since we handle everything in-house from mold making to machining, we can reduce mold costs and inter-process costs compared to outsourcing. As costs vary depending on the method, we will also suggest transitioning from machining to 3D printing. (For reference: transitioning from machining requires more than 5 pieces, and transitioning from 3D printing requires more than 2 pieces for cost reduction.)
Price range
P2
Delivery Time
P4
※Since we have in-house production from mold making to machining, there is no waiting for outsourcing, and we can ship in as little as 3 weeks. Please consult us if you are in a hurry, as the time may vary depending on the shape and quantity.
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 finish) ■ 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 / Comprehensive support from wooden pattern design, casting to machining based on drawings only) ■ 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】 - I want to consolidate orders for wooden patterns, casting, and machining to one company. - I want to entrust everything from drawings to mass production. - Producing single repair parts for discontinued products. - Replicating parts that only exist in physical form without drawings. 【Achievement Scale】Over 500 prototypes 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.
