Physical replication of parts without drawings | Consistent process from 3D scanning to casting and machining.
Selection based on the material of the actual item (10 types of aluminum alloys / 8 types of copper alloys)
I want to replicate a part that only has the physical object and no drawings. I will measure the shape with the latest 3D scanner and replicate it consistently through casting and machining.
Have you ever been turned down for the replication or production of substitute parts that only exist in physical form, like products from other companies or discontinued items, because you didn't have the drawings on hand? To replicate parts without drawings, it is necessary to measure the shape of the physical object with high precision and reverse-engineer it into 3D CAD data. If the measurement accuracy is low, it cannot be reflected in the mold design that accounts for shrinkage during casting, resulting in replicas that do not match the dimensions. Karmo Casting measures the physical object with high precision using the latest 3D scanners, including non-contact three-dimensional digitizers, and then converts it into 3D CAD data. We handle everything in-house, from mold design to casting, machining, and inspection. By completing the entire process from measurement to mass production in-house, we can reflect the shrinkage amount in the mold design. This product is an example of reverse engineering where we obtained the shape of another company's product from a state without drawings through 3D scanning and consistently replicated it through 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
【Scanning Equipment】High-precision measurement of actual items using the latest 3D scanner and non-contact three-dimensional digitizer (deviation 50-80μ) 【Supported Quantity】From 1 piece 【Supported Size】From 50mm square to 1,000mm square 【Supported Materials】Selected according to the material of the actual item - 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) 【Casting Process】In-house capabilities for 5 methods: sand casting / self-hardening / alkaline phenolic / cold box / mold 【Machining】15 units of 5-axis machining centers, 2 gantry-type machining centers, 3 vertical machining centers, 2 NC lathes 【Inspection】2 contact-type three-dimensional measuring machines, 1 non-contact three-dimensional digitizer (deviation 50-80μ) 【Certification】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2 【Items to Prepare When Inquiring】Actual item (real machine parts) or photos of the actual item. Drawings are not necessary. We also accommodate NDA agreements.
Price information
If you provide the actual item, we will measure its shape with a 3D scan and give you a free estimate. Even for parts without drawings, we can complete the mold design in-house, taking shrinkage into account, ensuring dimensional accuracy for the replicas. We can accommodate production from a single piece, and by manufacturing the molds in-house, we keep initial costs low even for small quantities.
Delivery Time
P4
※The initial process, including 3D scanning and mold design, takes a minimum of 3 weeks. It may vary depending on the complexity of the shape, so please consult us first.
Applications/Examples of results
【Applicable Industries】Automotive・CASE / Railways / Aerospace / Marine / Semiconductors・Communication Equipment / Robotics / Machine Tools / Agricultural Machinery / Industrial Machinery 【Delivery Achievements】 ■ Reverse engineering of industrial machine parts from other companies (AC4CH / Replication from 3D scans of physical items without drawings) Measured shapes with the latest 3D scanner and reflected shrinkage in mold design ■ Bracket for industrial machinery equipment (AC4B-F / L250×W180×H80) Guaranteed both casting accuracy and machining accuracy through dimensional measurements immediately after casting and after machining ■ Housing for industrial machinery equipment (AC4CH / L300×W600×H150 / Wooden mold・Sand mold) Reduced machining allowance to prevent warping. Thick sections are cooled to suppress shrinkage cavities 【Used in Such Situations】 - Want to replicate parts that only exist physically without drawings - Want to produce substitutes for discontinued products or products from other companies - Have been refused replication or reverse engineering - Want to achieve both wooden mold costs and integrated production 【Outside Scope of Services】 We do not handle cast iron or cast steel (we specialize in aluminum alloys and copper alloys). Please consult us for large castings exceeding 1,000mm square.
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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.
