Improvement in both cost and quality [Changing from cutting & sand casting to digital casting]
There are no drawings for the parts, and the processing company has gone out of business... If you are having trouble with metal parts, please consider "Digital Cast," a mold-less casting solution.
The image is an example of manufacturing an elephant trunk (the part used for the handles and tips of rickshaws) by Digital Cast. The previous material was brass, and it was manufactured through cutting, but the processing company reportedly went out of business. After that, it was manufactured once using sand casting, but it was expensive compared to cutting and had many defects, which was a problem. Therefore, we proposed Digital Cast, which can handle small lots, and were able to improve both cost and quality. 【What is Digital Cast?】 A method of producing metal products by creating resin models with a 3D printer and then following a process similar to lost-wax precision casting using those models as prototypes. Castings can be produced in as little as one week, starting from just one piece. We offer proposals that are beneficial even for development and prototyping. If you have parts under consideration for weight reduction or shape changes, please feel free to consult with us. 【Three Features of Digital Cast】 - Fastest delivery time of one week (usually two weeks) - Zero mold cost - Production possible from a minimum of one piece
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basic information
Traditional methods Cutting processing and sand casting Industry: Tourism Material: SCS13
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Applications/Examples of results
【Examples】 Industrial machinery, semiconductor parts, golf club heads, turbochargers, prototype verification of complex shapes, strength verification of cast products, prototype verification with material changes, original parts manufacturing. 【Details of Examples】 ■ Cost Reduction of 80% GG Manifold (Aerospace Component) Two parts were manufactured through machining and then welded together. Due to the use of special materials, they were sourced from overseas processing companies, resulting in high costs. This was resolved with digital casting. With a wide range of compatible materials and integrated molding, there was a significant reduction in costs along with improved quality due to enhanced strength. Material: Inconel 625, Conventional Method: Machining + Welding ■ Short Lead Time Turbine Impeller Parts (Industrial Turbine) For large parts with a diameter of 380mm, traditional methods required 1 to 2 months for mold production. However, with digital casting, cast products can be produced without molds, significantly improving lead times. Additionally, it can accommodate special materials such as heat-resistant steel and duralumin. Material: SCS13 ■ Prototype Verification Vehicle Development Prototypes (Next-Generation Mobility) Initial costs associated with mold production and quality concerns after mold creation were resolved with digital casting. Verification of cast products was conducted without molds, alleviating quality concerns. Material: FCD
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Company information
With a posture of "just half a step" without complacency, we have cultivated "lost wax precision casting" over many years. In 1991, we obtained a U.S. patent for "MIM (Metal Injection Molding)." Utilizing 3D printing technology, we offer next-generation precision casting technology called "Digital Cast." We provide optimal proposals through various technologies! We thoroughly support our customers' manufacturing processes! We specialize in complex three-dimensional shapes in small lots of various types and carry out everything from mold making to casting, machining, and simple assembly in-house. We supply products to various industries, including medical devices, semiconductors, machine tools, and aerospace. "Just make it, from one piece." We can propose a wide range of manufacturing methods from prototype production of one piece to mass production. We enable time savings in searching for various suppliers and considering consultation destinations, becoming a true total cost reduction partner by proposing reductions in management costs associated with consideration time and product costs. More than half a century ago, Castem's casting began with handmade machine tools. Today, we have become a company with the top domestic share in the manufacturing of general industrial parts using lost wax and are also engaged in the production of micro lenses and micro needles using the world's highest precision 3D light shaping technology.
