We Deliver Rapid Prototype Castings with the Fastest Turnaround Times

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About KFA

Kimura Foundry America (KFA) provides added value for all rapid prototype castings with the shortest delivery times and a high value of service to meet the specific production requirements of any application. On a mission to be the number one foundry in the USA for rapid prototyping castings and small-volume production castings, Kimura utilizes the most up-to-date technology and integrated operations to ensure the delivery of quality castings. With a goal to serve as a role model for foundry production, Kimura strives to realize zero defect products with state-of-the-art technologies that continue to push industry boundaries.

Specializing in quality castings optimized with 3D printing technology, Kimura incorporates a long history of foundry success and a patented sand material that enables us to produce top-quality, defect-free rapid prototype castings in as little as 5 business days. In addition to 3D printed sand molds and cores, high speed casting simulation software and various inspection capabilities, including in-house CT scanning, strengthen our quality standard. We supply rapid prototype castings made of cast iron, cast steel, aluminum and numerous specialty alloys and our process is ideal for rapid prototyping, small volume production, and service parts when a conventional pattern is not available or applicable.

Fully embracing additive manufacturing as the cornerstone of the next industrial revolution, Kimura Group today has six ExOne sand 3D printers for sand core and mold production at our parent company in Japan and three at the Kimura Foundry America, where we began operations in late 2018 at our Shelbyville foundry designed entirely around the 3D sand binder jetting technology.

Benefitting from nine decades of experience in sand casting innovation in Japan, Kimura Foundry America was established in Shelbyville, Indiana on November 7th, 2018 with a mission to deliver top-quality rapid prototypes.

Our journey into 3D printed sand castings started almost a decade ago in Japan, where our parent company has a rich history of foundry leadership. The Kimura Foundry Group continues to build on nine decades of metal casting experience that saw it innovate from full-mold castings to the adoption of indirect additive manufacturing for rapid prototyping, and enlarging the material variety from cast and steel iron to aluminum.

More demand rising for rapid prototype castings, Kimura Foundry America seeks all the possibility to recognize the benefits additive manufacturing based on the centuries-old sand casting process, allowing us to stay agile to the needs of our customers. Our facility in Shelbyville, Indiana was designed with ExOne binder jetting machines at the heart of operations. We focus exclusively on 3D printing to produce sand molds and cores, doing away with the need to use patterns to create tooling thus drastically reducing the lead times for functional prototypes with production quality.

The fast turnaround times of our binder jetting machines required us to further invest in supporting technologies to better serve our customers throughout the prototype development process. To guarantee quality and fast delivery, we offer an A-to-Z production approach with all the process steps in-house. Our foundry offers engineering, mold design, simulation, 3D printing, cleaning, assembly, metal pours, finishing, and quality control all under one roof to strategically support the automotive, construction machinery, pump, and industrial equipment industries we serve.

Fast Delivery

Delivering rapid prototype castings in less than one week is a gamechanger for iron and aluminum casting, opening the door to quicker product development and new freedom of design. By concentrating our sandcasting capabilities under one roof, we can iterate designs quickly based on casting results and can communicate with customers and provide feedback to support their needs for unique runner and riser designs or other difficult requirements. Using MAGMASOFT® solidification modeling, our engineering team tailors vents and risers to the part while running flow and solidification analysis to confirm the pour capabilities in advance to ensure quality castings. What’s more, with our ExOne 3D printers we can do undercuts and cores which would not be able to be created with traditional foundry practices.

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Quality-Assurance

Quality is the main pillar of our rapid prototype castings. Being a one-stop shop is not only beneficial for production speed, but also quality. Because we do everything under one roof, we have a good line of communication between all the process steps and the crucial lines of feedback between our design, casting, and quality departments ensures customer requirements are met or exceed for each piece. Our engineers evaluate castings and analyze designs very quickly without delays caused by outsourcing to external vendors

Our in-house lab offers the ability to carry out Brinell, tensile, metallography, surface scan, leak, ultrasonic, and penetration testing. With a CT inspection system for precise internal evaluations, we also assess parts with non-destructive methods to guarantee quality castings. Having this ability also means we can provide direct feedback to our engineering team on how accurate the pre-casting simulations are while reducing material waste without the need to section cast parts for testing.

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