Integrated production from casting molds to processing | Industrial machine parts from 1 piece | 15 units of 5-axis machining centers
AC2A-F
Are you machining parts that are only needed in small quantities for each model? We handle everything from molding to processing in a consistent manner, casting from one piece, and finishing with 15 units of 5-axis machining centers.
Parts for industrial machinery, such as housings, brackets, and covers, often require only a few units per model. Due to the costs associated with casting, companies continue to machine from block materials, leading to increased material costs and processing time. Is this situation familiar to you? The reason small quantities do not become castings lies in the assumption that molds and machining are arranged separately. When the ordering sources for molds, casting, and machining are divided, initial costs and the effort of arrangement arise for each project, making machining appear faster and cheaper. Karmo Casting is a foundry manufacturer that handles everything in-house, from the production of wooden and metal molds to casting, machining, and inspection. We design casting shapes that minimize machining allowances and finish multiple surfaces using a 5-axis machining center, reducing the amount and processes of material removed. We have five casting processes from sand molds to metal molds, allowing us to choose the method that fits the quantity and shape. We accept everything from single prototypes to additional production runs for the same model under the same system. We are offering free downloads of case studies on cost reductions achieved by switching from machining to casting, as well as a guidebook on measures against casting defects. Please download 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 【Lot Size】From 1 piece (additional production and single item production of repair parts are also possible) 【Casting Size】From 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 - Machining Only: SCS13 / FCD450 / A5052 【Casting Process】Green sand / Self-hardening / Alkaline phenolic / Cold box / Molding 【Machining Equipment】15 units of 5-axis machining centers (6 with pallet changers) / 2 gantry machines / 3 vertical machines / 2 NC lathes 【Machining Precision】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 drawings or actual samples of the machined products, we will offer a free estimate along with the shape in case of casting. The guideline for cost reduction is to convert from cutting processes for 5 or more pieces and from 3D printing for 2 or more pieces. Since we manufacture the molds in-house, we can keep initial costs low even for small quantities of each model.
Delivery Time
P4
※The prototype can be shipped in as little as 2 weeks, and the initial production including mold making takes a minimum of 3 weeks. If switching from a 3D printer method, it can be done in as little as 1 week. Please let us know your desired delivery date, as it may vary depending on quantity and processing locations.
Applications/Examples of results
【Industries Served】Industrial Machinery / Machine Tools / Agricultural Machinery / Robotics / Marine Vessels / Railways / Power & Energy / Automotive & CASE / Semiconductors & Communication Equipment 【Achievements】 ■ Aluminum parts for agricultural machinery (AC4A-T6 / High precision finish) ■ Aluminum parts for marine vessels (AC2A-T6 / Small size, large quantity) ■ Cylinder cases for railway vehicles (AC4CH-T6 / Complex shapes) ■ Copper alloy castings for power equipment (CAC406 / Thin-walled, internal passages) 【Applications】 - Switching from machining to casting for housings and covers for several units per model - Creating a single repair part for discontinued machinery from the actual item - Consolidating orders for molds, casting, and processing to reduce procurement effort - Producing small quantities of the same part with each additional order 【Scale of Achievements】200 companies and 5,000 items over the last 5 years. More than 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.
