Integrated production from casting molds to processing | Semiconductor parts from 1 piece with 15 units of 5-axis machining centers.
AC4CH/AC4C/AC4B/AC2A/AC7A and other 10 aluminum alloys, copper alloy CAC8.
The casting and processing locations are separate, making it difficult to trace the cause of dimensional discrepancies. We manufacture from one piece with a consistent in-house process from molding to machining, using 15 five-axis machining centers, and prototypes can be shipped in as little as two weeks.
Casting goes to the casting manufacturer, and machining goes to the machining manufacturer. Have you ever experienced having to redo a prototype because the dimensions of parts for a semiconductor device arranged separately did not match, without knowing where the cause lies? The cause lies in the fragmentation of the process. The casting side is unaware of the machining standards, and the machining side does not know the individual differences in the castings. Variations in machining allowances and misalignment of internal shapes arise where information is interrupted between processes. The more ordering parties there are, the more the effort and lead time for arrangements accumulate. Karmo Casting is a foundry that handles everything in-house, from the production of wooden and metal molds to casting, machining, and inspection. By deciding on the casting plan with machining standards in mind and organizing the setup with knowledge of the state of the castings, information does not get interrupted between processes. Multi-surface machining is done with a 5-axis machining center to minimize setup times, and dimensions are verified with a three-dimensional measuring machine before shipping. Communication is streamlined through a single point of contact, and we accommodate prototypes starting from just one piece. Factory tours before contract signing are also possible. We are offering a collection of case studies demonstrating weight reduction and cost reduction achieved through integrated production, as well as a guidebook for addressing casting defects, free of charge. Please download them from the link below.
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basic information
【Scope of Services】 Production of wooden and metal molds / Casting / Machining / Integrated production of inspection (processing only; cutting of supplied materials is also acceptable) 【Lot Size】 From 1 piece 【Casting Size】 50mm square to 1,000mm square / Minimum thickness 1mm (local) / 1.5mm (overall) 【Supported Materials】 - Aluminum alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B - Copper alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 - Processing only: SCS13 / FCD450 / A5052 【Casting Processes】 In-house capabilities for five methods: sand mold / self-hardening / alkaline phenol / cold box / metal mold 【Machining Equipment】 15 units of 5-axis machining centers (6 with pallet changers) / 2 gantry machines / 3 vertical machines / 2 NC lathes 【Machining Accuracy】 Geometric tolerance ±0.03mm 【Inspection Equipment】 2 contact-type 3D measuring machines / Non-contact 3D digitizer (deviation 30-80μm) / 3D scanner NIMBLETRACK Gen2 【Certifications】 ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2
Price information
If you provide us with the processing drawings (even if there are no casting drawings), we will give you a free estimate. By handling both casting and processing together, we can reduce the hassle of separate arrangements for contact, transportation, and inspection. A guideline for cost reduction is to switch from cutting processing with more than 5 pieces or from a 3D printer with more than 2 pieces. A factory tour before the contract is also possible.
Delivery Time
P4
※Prototypes can be shipped in as little as 2 weeks, while the initial order including mold production takes a minimum of 3 weeks. If switching from 3D printing, it can be done in as little as 1 week. Please note that the timeline may vary depending on the shape, quantity, and processing locations, so let us know your desired delivery date.
Applications/Examples of results
【Applicable Industries】Semiconductor manufacturing equipment / Communication devices / Industrial machinery / Machine tools / Robotics / Railways / Ships / Aerospace / Automotive and CASE / Power and energy 【Achievements】 ■ Base and pedestal for semiconductor manufacturing equipment (AC4CH) ■ Motor housing for automotive EVs (AC4B-T6) ■ Cylinder case for railway vehicles (AC4CH-T6 / complex shapes) ■ Copper alloy castings for power equipment (CAC406 / thin-walled, internal passages) 【Used in Such Situations】 - Casting and machining are ordered separately, making it difficult to identify the cause of defects. - In prototyping semiconductor equipment, wanting to create just one base or frame. - Wanting to consolidate suppliers to reduce the hassle of arrangement and inspection. - Replacing machining with casting to reduce material waste. 【Achievement Scale】200 companies and 5,000 items in the last 5 years. Over 500 prototypes and development achievements annually.
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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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