Small lot production of castings | Consistent support from pattern design to aluminum sand mold casing.
AC4B-F
Isn't it ambiguous whose responsibility it is, the casting accuracy or the machining accuracy? We provide consistent support from pattern design to machining, ensuring the accuracy of the AC4B-F casing.
Have you ever experienced the difficulty of not knowing whether the cause of defects in parts, such as casings for industrial machinery, lies in casting or machining, especially when both casting precision and machining precision are critical? When the casting manufacturer and the machining manufacturer are separate companies, the machining side ends up individually addressing the dimensional variations of the castings, which can lead to delays in feedback. If mass production begins while the boundary of responsibility for precision assurance remains ambiguous, it complicates the investigation of defect causes. Karmo Casting handles everything in-house, from the design and production of wooden and metal molds to casting, machining, and inspection. By measuring dimensions both immediately after casting and after machining, we can reflect the trends of variations in machining conditions, thereby ensuring both casting precision and machining precision as a unified guarantee. With a single point of contact, the investigation of causes when defects occur is also expedited. This product is an example of an aluminum sand casting casing made from AC4B-F material, which has been consistently handled from mold design to machining, including precision assurance. We are offering a technical document summarizing the break-even analysis by method and considerations for small lot production free of charge. Please download it from the link below.
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basic information
【Wood Pattern Design】Consistent in-house response from mold design (shape changes also completed in-house) 【Supported Quantities】From a single prototype to mass production of 30 units per month We handle the transition from prototype to mass production with the same system 【Product Size】600mm × 500mm × 300mm (Aluminum sand casting casing for industrial machinery) 【Accuracy Guarantee】Dimensional measurements taken both immediately after casting and after machining, guaranteeing both casting accuracy and machining accuracy together 【Supported Materials】 - Aluminum Alloys: AC4B-F / AC2A / AC2B / AC3A / AC4A / AC4C / AC4CH / AC4D / AC7A / AC8B (10 types) 【Casting Process】Self-hardening / Alkaline phenol / Cold box 【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 (deviation 50-80μ) 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2 【Items to Prepare When Inquiring】 Drawings (STEP / IGES / PDF) or photos of the actual item. If there are no drawings, approximate dimensions, materials, and quantities are sufficient. We also accommodate NDA agreements.
Price information
If you provide us with drawings or actual samples, we will give you a free estimate. We can accommodate production starting from one piece and reduce initial costs by manufacturing the molds in-house. Since costs vary depending on the manufacturing method, we will also suggest alternatives for switching from machining, die casting, or 3D printing. (For reference: Switching from machining requires a minimum of 5 pieces, and switching from 3D printing requires a minimum of 2 pieces for cost reduction.)
Price range
P2
Delivery Time
※The initial process, including mold design and manufacturing, takes a minimum of 3 weeks. It may vary depending on the required precision, so please consult us first.
Applications/Examples of results
【Applicable Industries】Industrial machinery, electrical equipment, plants, etc. 【Delivery Achievements】 ■ Housing for industrial machinery equipment (AC4CH / L300×W600×H150 / wooden pattern, sand mold) Reduced machining allowance to prevent warping. Cooling metal used in thick sections to suppress shrinkage cavities. ■ Casing for industrial machinery equipment (AC4B-F / L300×W250×H200) Cooling metal placed in thick sections to address shrinkage cavities. ■ Bracket for industrial machinery equipment (AC4CH / wall thickness 3mm) High-precision casting used to avoid tapping breakage in small diameter bosses. 【Used in Such Situations】 - Ambiguity over whether the responsibility lies with casting precision or machining precision. - Time-consuming investigation of defects due to separate companies handling casting and machining. - Desire to achieve both wooden pattern costs and integrated production. - Replication of parts that only exist as physical items without drawings. 【Achievement Scale】Over 500 prototype and development achievements annually. 200 companies and 5,000 items in the last 5 years. 【Out of Scope】 We do not handle cast iron or cast steel (specializing in aluminum alloys and copper alloys). For large castings exceeding 1,000mm square, please consult us.
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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.
