NC Model Casting
Kochi Kigata Kogyo Co.,Ltd.

Certifie to ISO19001

Head Office and Main Plant

1244-1, Kagamicho-Shimobun, Konan-shi,
Kochi-ken, Japan 781-5452
TEL. 0887-50-3988
FAX. 0887-55-3906

Dalian Office

ganjingzi district spicy 寨東 Street No.7
Dalian, China 116039


Extensive cost reduction has been made possible by designing and producing molds after taking into account all the processes involved, from the selection of materials to machining and assembly.

When thinking of cost reduction in terms of modeling, you might first think of cutting the mold cost. However, we do not become fixated simply on the mold cost model itself, but focus on overall cost reduction through a modeling strategy that takes the entire manufacturing process into consideration, from the selection of raw materials to machining and assembly.

Cost savings through improved efficiency and time reduction

In a scenario of producing 100,000 products in one year, it is possible to save approximately 278 hours annually by reducing the time to manufacture one product by 10 seconds. Calculating this at 3,600 yen per hour results in a total cost savings of around 1,000,000 yen.

Overall improvement of efficiency and decrease of manufacturing failure rate

We aim to reduce the time taken for machining, assembly, snagging and shipment of materials and also to decrease the manufacturing failure rate. In the current age, those specializing in “designing”, “molding”, “casting”, “machining” and “assembly” must not simply think of reducing their individual costs separately. NC Model Cast utilizes its wisdom in all possible ways with the aim of improving the overall efficiency and decreasing the manufacturing failure rate. While doing this we also work to avoid becoming fixated only on the mold cost, which normally comes up as one of the first issues that needs to be addressed.



Advantages of digital centralized management

Discussions and presentations using mock-ups
In preliminary meetings with clients before casting production, or when we propose our ideas based on the result of VA (Value Analysis) to clients, we not only use drawings but also show mock-ups of either actual size or several scales down to make our meetings and presentations more efficient and easier to understand. Instead of putting time and effort into creating the raw materials for demonstration like we used to do in the past, we consider these mock-ups to be the same as the real mold, and use them to confirm with the clients the specific dimensions and shapes they desire. These mock-ups are, in some cases, also used for final review before going into mold production.

Speeding up the development process, and realizing maximum productivity from the start
Through our technology utilizing 3D printing, we can create a solid model of identical shape to function as the mold before casting, and this is especially beneficial for projects that require complex machining. A jig that takes many days to develop can be manufactured at an early stage before the raw material becomes available for production, enabling us to manage the jig development phase concurrently with the molding and casting phases. This is how we can speed up the entire development process, and realize maximum productivity from the start. In addition, we are now developing a quicker-than-ever "Quick Cast" technology that will enable casting without mold by combining lost-wax casting and Shaw process casting.


Cost reduction by shifting to casting from steel plates and FCD, and production of casting materials without the need for molding

Currently, it appears that many development projects are using steel plating or FCD to manufacture cast products. We think that cast steel products are far preferable for pursuing extensive cost reduction, considering that cast steel is easier to weld than FCD and creates lighter products than steel plating (which is limited in variety), in addition to its superiority in heat resistance, shape rigidity and flexibility in design.

Thinking of material cost in grams
Conventional methods of processing based on pressing and welding steel plates has several constraints. There are not many options in steel thickness. Configurable shapes are also limited. To give sufficient rigidity, including the prevention of distortion, the steel plate may end up becoming thicker than cast steel, and more expensive, considering the recent price hike of stainless steel. From the standpoint of increasing material cost, we should realize that we need to start thinking of raw materials in grams, instead of in tons or kilograms.

1. Can be welded

2. Can create lighter products than steel plating (which is limited in variety) For example: If a steel plate with a thickness of 6t is not sufficient, the next available thickness is 9t. But if 7t is sufficient for the strength required by the client, the additional 2 mm of 9t steel plate will be excessive quality for this client’s project.

3. We believe that we can slash the total production cost by using cast steel, considering its superiority in heat resistance, shape rigidity and flexibility in design.
Development without the need of creating a mold for casting
We believe flexibility in design will be the most important challenge from here on. If the client requests free-form shaping, using steel plating will end up making the project more costly. The designer of the project would not want to spend much on mold cost for developing a prototype as a test model (not for mass production), but is actually interested in trying out his design and seeing if it works or not, if the budget allows. We have come up with a development method that does not require us to create the mold for manufacturing cast products using steel plating or FCD.

If we have solid data, we can produce your casting material in around two weeks. Moreover, we can also create three-dimensional solid data from DFX data. Our unique methodology is most suitable for clients who feel dissatisfied with just the analysis and no real machine testing, but want to gain a comprehensive evaluation of their development plan in order to allow for alterations.

Prototyping for development (1): Lost-wax casting using laser molding systems
Material used: SCMnCrM2B
Conventionally, FCD500 was used to create the material by high-frequency quenching and machining. While only 2 to 3mm of the surface can be quenched with FCD, we can expect the above material to be quenched to at least 45 with HRC. For testing of the prototype created in the development phase, we used the black skin.

Lost-wax casting normally involves the use of aluminum molds and takes 1.5 to 2 months to complete. In our test phase, we finished creating the lost-wax cast in a few hours by using a laser molding system. In this method, wax is directly pressed in the cast created from the 3D printing system .

Due to this unique prototyping method, we were able to significantly shorten the development process, including burring, and deliver the material in two weeks. Simply put, this is the most suitable approach that can be taken to create trial materials for further examination in design to solidify the final development plan.