Digital casting with 3D printing and casting can produce castings in as little as one week, starting from one piece.
【Conventional Method】 Cutting Process 【Method】 Digital Cast 【Content】 This is a case study conducted when proposing shapes with an eye toward mass production. Digital casting, which allows for the creation of cast products from a single piece without molds, enables such shape modifications and prototypes to be made with low risk, providing peace of mind. We were able to produce test parts using the same method as mass production. 【What is Digital Cast?】 A method that involves creating a resin model with a 3D printer and then manufacturing metal products following a process similar to lost-wax precision casting using that model as a prototype. Castings can be produced in as little as one week, starting from just one piece. We offer proposals that are beneficial even in 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】 - Shortest delivery time of one week - Mold cost of zero yen - Capable of manufacturing from just one piece ～～～～～～～～～～～～～～～～～～～～ Industry: Semiconductor Material: SCS13
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**Digital Cast of Castem** ■ Process 1. 3D Printing Shape the model using a 3D printer (resin material) 2. Ceramic Coating Coat the wax tree with ceramic liquid and powder in about 4 to 6 layers 3. Mold Firing Completely eliminate the 3D printed model at high temperatures and fire the ceramic mold 4. Casting Pour molten metal into the mold ■ Supported Size Up to 500 mm square ■ Steel Types We can accommodate a wide range of needs, including iron, stainless steel, aluminum, copper (including pure copper), special alloys (such as duralumin A7075 and nickel alloys), heat-resistant steel, tool steel, and high-speed steel.
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[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 [Example Details] ■Short Delivery Time Turbine and impeller parts (industrial turbines) For large parts with a diameter of 380 mm, traditional mold production required 1 to 2 months, but with the digital casting method, cast products can be produced without molds, significantly improving delivery times. Additionally, it can accommodate special materials such as heat-resistant steel and duralumin. Material: SCS13 ■80% Cost Reduction GG manifold (aerospace parts) Two parts were manufactured through machining and then welded together. Due to the special material, they were sourced from overseas processors, resulting in higher 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 quality improvements due to increased strength. Material: Inconel 625, Traditional Method: Machining + Welding ■Prototype Verification Vehicle development prototypes (next-generation mobility) Initial costs due to 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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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.