Rapid Prototype and Small Lot Production

Today’s manufacturers demand faster and more complex casting solutions. To answer that challenge, Kimura is your “single-source” solution for the design, production and delivery of rapid prototype (RP) castings and small lot production castings. Our engineers work closely with you to develop and finalize your designs. Raw castings are produced with zero defects in just 5 days — ready for immediate shipment to your facilities in North America and worldwide.

Precision Iron, Cast Steel and Specialty Alloy Castings

Use of 3D printing technology for rapid prototyping is commonplace today. But to make it truly effective for engineers and other buyers who need high precision, high complexity castings on demand—either a few RP castings or highly specialized castings in relatively small numbers —Kimura Foundry developed its own proprietary technologies.

The result: once design is completed, it takes just five days to produce molds, cast the parts, perform finishing and final inspection. This may be followed by machining operations. Castings can be made from Gray Iron, Ductile Iron, Ni- Resist, Stainless Cast Steel, Aluminum and Other Specialty Alloys. They can feature:

  • Highly complex shapes
  • Wall thicknesses as low as 1.5mm
  • Dimensional accuracy ±0.5mm
  • Internal cooling structures for castings
  • Exceptionally smooth surfaces and defect free castings

Kimura produces castings to the highest global standards because of its more than 90-year tradition of best foundry practices combined with modern engineering, IT and its patented intellectual property.

Its focus has been on three fronts:

  • USA and Japan patents on Kimura’s development of artificial sand that creates molds free of veining, burrs and other defects—and significantly lowers production costs.
  • Sophisticated pouring and cooling standards that ensure uncompromised product integrity.
  • Use of the latest Magma simulation software which tracks all aspects of pouring, solidification and casting quality.

Kimura’s RP castings are designed produced on the company’s four ExOne 3D printers

Total production costs are reduced, making RP and small lot castings very competitively priced.

 

Samples of Kimura Foundry RP castings
Samples of Kimura Foundry RP Castings
Casting production using artificial sand
Kimura Foundry has innovated on many fronts of casting production including artificial sand
A machine used for rapid production
Kimura’s Izu, Japan, Advanced Manufacturing Center houses state-of-the-art rapid production technology

 

Casting mold substrate cost comparison

Delivery of RP and small lot production castings has been reduced by 8x versus traditional casting. Design to production to delivery times now stand at just a few weeks. Faster than competitors in Europe and the USA.

Conventional casting manufactruing process

Because of Kimura’s rapid delivery, quality and price combination, sales in Japan have grown dramatically.

DMP revenue

Material Standard Correspondence Table

Stainless Cast Steel

ISO JIS ASTM EN Steel Number
GX4CrNi12-4 SCS6 CA6NM 1.4317
GX5CrNi19-9 SCS13 CF8 1.4808
GX5CrNiMo19-11-2 SCS14 CF8M 1.4408
SCS18 CK20

Heat Resistant Cast Steel

ISO JIS ASTM EN Steel Number
GX40CrNiSi22-10 5CH12X HF 1.4826
GX40CrNiSi25-12 SCH13X HH typell 1.4837
G40CrNiSi25-20 SCH22X HK,40 1.4848
GX4ONiCrSiNb38-19 SCH30XNb HU 1.4849

Flake Graphite Cast Iron

ISO JIS ASTM EN
SO 180/JL/200 FC150 Class No.150B EN-GJl-150
SO 185/JL/200 FC200 Class No.200B EN-GJL-200
SO 185/JL/250 FC250 Class No.250B EN-GJL-250
ISO 185/JL/300 FC300 Class No.300B EN-GJL-300

Spheroidal Graphite Cast Iron

ISO JIS ASTM EN
400-18S FCD400-18 60-40-18 EN-GJS-400-18
450-10S FCD450 -10 65-45-12 EN-GJS-450-10
500-7S FCD500-7 80-55-06 EN-GJS-500-7
600-3S FCD600-3 80-60-03 EN-GJS-600-3

Vermicular Graphite Cast Iron

ISO JIS ASTM EN
ISO 16112/JV/350 FCV350 350 EN-GJV-350
ISO 16112/JV/400 FCV400 400 EN-GJV-400

Ni-resist Cast Iron

International
Trade Name
ISO JIS ASTM EN
Ni-Resist D-2 JSA/XNi20Cr2 FCDA-NiCr 20 2 Type D-2 GJS-AXNiCr20-2
Ni-Resist D-5S JSA/XNi35Si5Cr2 FCDA-NiSiCr 35 5 2 Type D-5S GJS-AXNiSiCr35-5-2