Small lot production of castings | Consistent support from pattern design to production of prototype oil filters
AC4B-F
Are you being turned down for the cost of trial molds and setup? We provide comprehensive support from mold design to machining, and we can also prototype the AC4B-F oil filter in the shortest time possible.
Have you ever been turned down for prototyping parts with a wide variety of shapes, such as oil filters for industrial machinery, due to costs associated with wooden molds and setup? Manufacturers that outsource wooden molds often face adjustments with their subcontractors every time there is a shape change or modification during the prototyping stage, leading to increased costs and time. In prototypes where the shape is not finalized in one go, this burden of adjustment becomes particularly significant. Karmo Casting handles everything in-house, from the design and production of wooden molds and metal molds to casting, machining, and inspection. We possess five casting processes in-house: sand molds, self-hardening, alkaline phenolic, cold box, and metal molds, allowing us to respond immediately to shape changes internally. By consolidating points of contact, we can offer short lead times and low costs even for prototypes. This product is an example of an oil filter made from AC4B-F material, handled consistently from wooden mold design to machining, and responding to shape evaluations during the prototyping stage. We are offering a technical document summarizing the break-even point by manufacturing method and considerations for small lot production for free. Please download it from the link below.
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basic information
【Wood Pattern Design】Consistent in-house support from design of wood patterns and metal molds (shape changes and modifications are also completed in-house) 【Lot Support】Prototype support from 1 piece 【Casting Size】50mm square to 1,000mm square / Minimum thickness 1mm (local) and 1.5mm (overall) 【Product Size】200mm × 150mm × 90mm (oil filter for industrial machinery) 【Supported Materials】 - Aluminum Alloys: AC4B-F / AC2A / AC2B / AC3A / AC4A / AC4C / AC4CH / AC4D / AC7A / AC8B (10 types) - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 (8 types) 【Casting Process】In-house possession of 5 methods: sand casting / self-hardening / alkaline phenol / cold box / metal mold 【Machining】15 units of 5-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 3D measuring machines, 1 non-contact 3D digitizer (deviation 50-80μ) 【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 or physical samples, we will give you a free estimate. Since we handle everything in-house from mold design, we can keep costs and lead times down even for prototypes. If mass production is confirmed, there may be further cost reductions through a review of the manufacturing method. Please start by discussing the shape and quantity with us.
Price range
P2
Delivery Time
P4
※Prototype production, including mold design and manufacturing, can be shipped in as little as two weeks. If shape changes are required, we will respond immediately in-house. 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】 ■ Oil filters for industrial machinery (AC4B-F / Comprehensive support from wooden pattern design to machining / Prototyping) ■ Head covers for industrial machinery (AC2A-F / Comprehensive support from wooden pattern design to machining / Small-lot production) ■ Aluminum parts for agricultural machinery (AC4A-T6 / High precision finishing) ■ Cylinder cases for railway vehicles (AC4CH-T6 / Complex shape with 6 cores / Delivery time 2 weeks) ■ Copper alloy castings for power equipment (CAC406 / Thin-walled, internal passages, uneven thickness measures) 【Used in Such Situations】 - Refused due to costs and setup for prototype wooden patterns - Many shape variations, wanting to recreate wooden patterns each time - Want to evaluate multiple shapes before mass production - Duplication of parts that only exist as physical objects without drawings 【Achievement Scale】Over 500 prototyping 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.
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