Small lot production of castings | Comprehensive support from pattern design to production of copper alloy castings for industrial machinery.
CAC406
Are you struggling with air pressure leaks and gas defects from the thick meat section? We can prevent shrinkage cavities in advance through casting simulation and ensure the airtightness of your products.
Have you ever experienced air pressure leaks during airtightness tests after mass production of copper alloy castings with thick sections, such as those used in industrial machinery? Thick sections solidify more slowly than thin sections, making them more prone to gas defects and shrinkage cavities (internal voids) during cooling. These issues are often not detectable through visual inspection alone, and it is not uncommon for defects to be identified only after airtightness tests or actual assembly. Karmo Casting analyzes the solidification process and cooling rates in advance using casting simulations to identify areas where gas defects and shrinkage cavities are likely to occur. By reviewing the feeding and cooling plans and managing everything in-house from pattern design to casting, machining, and inspection, we can ensure airtight designs before mass production. This product is an example of a copper alloy casting for industrial machinery made from CAC406 material, consistently finished with measures against gas defects and shrinkage cavities in thick sections. We are offering a technical document summarizing the break-even points by method and considerations for small lot production free of charge. Please download it from the link below.
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basic information
【Mold Design】Consistent in-house support from mold and die design (shape modifications also completed in-house) 【Lot Size】From 1 piece 【Casting Size】50mm square to 1,000mm square / Minimum thickness 1mm (local) / 1.5mm (overall) 【Product Size】350mm × 150mm × 100mm (copper alloy casting for industrial machinery) 【Thick Section Measures】Predict gas defects and shrinkage cavities in advance through casting simulation. Ensure airtightness by reviewing riser and cooling plans 【Supported Materials】 - Copper Alloys: CAC406 / 403 / 502 / 301 / 302 / 303 / 702 / 703 (8 types) 【Casting Processes】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 machining centers, 3 vertical machining centers, 2 NC lathes 【Inspection】2 contact-type 3D measuring machines, 1 non-contact 3D digitizer (tolerance 50-80μ) 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2
Price information
If you provide us with drawings or actual samples, we will give you a free estimate. We will also conduct a casting simulation to pre-verify shapes where the airtightness of thick sections is a concern, and we will propose conditions that minimize gas defects and shrinkage cavities. Since we handle everything in-house from pattern design, we can keep costs and delivery times under control even if a revision of the plan is necessary.
Price range
P2
Delivery Time
※The initial process, including mold design and casting simulation, takes a minimum of 3.5 weeks. It may vary depending on the shape of the thick sections, so please consult us first.
Applications/Examples of results
【Applicable Industries】Automotive・CASE / Railways / Aerospace / Marine / Semiconductors・Communication Equipment / Robotics / Machine Tools / Agricultural Machinery / Power・Energy 【Delivery Achievements】 ■ Copper alloy castings for industrial machinery (CAC406 / Simulation analysis conducted for gas defects and shrinkage cavity measures in thick sections) ■ Copper alloy castings for marine applications (CAC406 / Thin core [passage] structure / Comprehensive support from wooden pattern design to machining) ■ Copper alloy castings for power equipment (CAC406 / Thin-walled, internal passages, measures against uneven thickness) ■ Oil filters for industrial machinery (AC4B-F / Comprehensive support from wooden pattern design to machining / Prototyping) ■ Cylinder cases for railway vehicles (AC4CH-T6 / Complex shape with 6 cores / Delivery time of 2 weeks) 【Used in Such Situations】 - Air pressure leaks from thick sections were discovered after mass production - Concerned about gas defects and shrinkage cavities and want to take preventive measures - Want to achieve both wooden pattern costs and integrated production - Replication of 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.
