Achieving coreless design through shape modification proposals to reduce costs and shorten lead times.
AC4B-F
Proposed a shape change to eliminate the core during the prototype development phase. When transitioning to mass production, we created a mold and further achieved cost reduction.
Due to the use of cores in the shape, casting costs and delivery times have increased, and have you ever considered cost reduction at the timing of mass production? Core structures not only increase mold costs and labor hours but also contribute to lower yields during mass production due to constraints on flow and strength. Karmo Casting designs and manufactures wooden and metal molds in-house, allowing us to provide consistent support from shape modification proposals to mass production transition. We possess 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 after eliminating cores. We provide comprehensive support for machining, inspection, and surface treatment after casting. This product proposes a shape modification for core elimination, and during the startup phase, we respond with sand casting due to the small quantity. In response to the increased demand accompanying the transition to mass production, we proposed mold creation, achieving cost reduction and lead time shortening. 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.
Inquire About This Product
Related Videos
basic information
【Method Transition】Elimination of cores through shape modification / During the startup phase, sand casting is used, and after transitioning to mass production, molds will be switched according to demand increase. 【Applicable Lot】From 1 piece 【Casting Size】50mm square to 1,000mm square / Minimum thickness 2mm (local) and 3mm (overall) 【Product Size】150mm × 200mm × 120mm 【Applicable 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 / mold 【Machining】15 five-axis machining centers, 2 gantry-type MCs, 3 vertical MCs, 2 NC lathes / Many achievements with geometric tolerances of ±0.03 【Inspection】2 contact-type three-dimensional measuring machines, 2 non-contact three-dimensional 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. By changing the shape to eliminate cores, we can reduce mold costs and labor hours, and when transitioning to mass production, we will propose further cost reductions through mold creation. Since costs vary depending on the manufacturing method, we will also suggest transitioning from machining or 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
※Shortening lead time through neutron reduction. During the startup phase, the shortest time is 3 weeks with a prototype, and it can be further shortened after transitioning to mass production with molds. Please feel free to consult with us.
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, mass production) ■ Aluminum parts for agricultural machinery (AC4CH-T6 / Core-less production through shape modification, initial production using sand casting) ■ Copper alloy castings for power equipment (CAC406, AC4CH-F, etc. / Thin-walled, internal passages, measures against uneven thickness) ■ Bases and pedestals for semiconductor manufacturing equipment (AC4CH-T6) ■ Motor housings for automotive EVs (AC4B-T6, A5052 / Cost reduction by switching from sand casting to die casting with mass production transition) ■ Resin wood patterns for sand casting (Delivery time 7 days / From 1 type) 【Used in Such Situations】 - Core structure costs and delivery times are a bottleneck - Want to prototype in small quantities using sand casting during the startup phase - Want to reduce costs by switching to die casting due to increased demand 【Achievement Scale】Over 500 prototypes and development achievements annually. 5,000 items from 200 companies in the last 5 years.
catalog（2）
Download All Catalogs
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.
