Mold fabrication

Ferrous & Non-Ferrous molds

We carry out design and fabrication of a variety of casting molds including green sand molds, self-hardening molds, gravity casting molds, shell molds, cold box casting molds, and more. We can also carry out fabrication of updated molds from existing, worn-out molds with no drawings or data through reverse engineering via a 3D scanner. We will provide you with the best quality, optimal format proposals and mold designs with added value based on specification, application, and cost needs through our ample experience, expertise, and comprehensive equipment lineup.

Utilization and application examples

Mass production casting molds / shell metal molds / prototype casting molds

Wooden Patterns

This department has built an impressive track record of achievements and a reputation for reliability since the company's founding. Large-sized wooden molds are a particular specialty of our company, and produced through a combination of NC processing machinery and the expert skills of our experienced craftspeople. We fabricate wooden molds for various ship hull construction cast parts, wooden molds for various machinery cast parts, wooden molds for pump parts, etc. We can accommodate a wide range of sizes from palm-sized molds to large wooden molds of several meters. We also carry out machining of 3 dimensional signs and 3 dimensional molded models (polystyrene foam, polyurethane foam) for amusement parks and other applications.

Utilization and application examples

Wooden molds for various ship hull construction cast parts / wooden molds for various machinery cast parts / pump parts / various 3 dimensional molded objects

Resin molds

These molds are fabricated by pouring a resin known as "metal resin", which is formed by mixing aluminum powder with an epoxy resin matrix, around a mold which is the same shape as the formed product. These molds have a higher durability than wooden molds, so they are often used as mass production molds for comparatively low quantity mass production, and are very suitable for small lot production such as for prototyping. These molds are less expensive than metal molds, and can be fabricated quickly as long as a master mold is available, and they also make mold revisions and shape changes easier, and so are well suited for situations where you require higher durability than wooden molds but cannot spare the expense or time required for metal molds.

Utilization and application examples

Agricultural machinery / industrial machinery / construction machinery / automotive machinery / design and art related

Shell molds

These casting molds are fabricated by thermally curing RCS (Resin Coated Sand), a type of casting sand with multiple types of resin added, in heated metal molds. Shell metal molds used for manufacturing are completely fabricated in-house at our company factory in order to achieve the highest degree of precision. We possess one of the largest large-size upright inverted shall machines in Japan which is able to handle even specialized large shells (up to a maximum of 150 kg). We can also provide processing using a cold box machine, which is primarily used for prototyping.

Utilization and application examples

Agricultural machine caterpillar components / engine components

We deliver to partner casting companies, who then carry out casting and
delivery products to agricultural machinery manufacturers

Agricultural machine caterpillar components / engine components

Materials

Digital Quick Casting

A precision casting method which utilizes laser molding products to eliminate the need for molds

Delivery in as short as 2 weeks after 3D data receipt!

Digital Quick Casting is an Kochi Kigata Kogyo Co.,Ltd. proprietary casting material fabrication method. 3D data provided by the customer is used to produce a laser molded product which is used as a master mold, which eliminates the need for 2-face divided molds for casting, and allows for fabrication of materials in shorter amounts of time. This method is recommended for cases when you require materials in the shortest possible time, such as for prototypes, presentation master models, and casting molds. The method is compatible with SC, SCW, FC, FCD, SCS, AC, and other materials.

Examples of prototyping using an SLA-7000 laser molding machine

Laser molding prototype models / From prototype models to products
Laser molding prototype models / From prototype models to products

Comparison of conventional prototyping method and D.Q.C method (up to materials)

Metal mold fabrication

  • Costs: Conventional costs
  • Delivery: Minimum of 6 weeks
  • Dimension accuracy: Φ100±1.0
  • 2-face divided molding increases the risk of mold deviation and core deviation
  • Requires time for modeling including processing margin and draft angle, etc.

D.Q.C fabrication

  • Costs: 1/3 the cost of metal mold fabrication
  • Delivery: Minimum of 2 weeks for even complex shapes
  • Dimension accuracy: Φ100±0.5
  • Provided material data is used as-is, allowing for reliable recreation of materials in the same shape with no re-modeling
  • No risk of mold deviation or core deviation
Example proposal for decreasing costs

Comprehensive cost reductions through vertical start-up using laser molding

Machinery and equipment

SLA-7000 laser molding machine

A device which forms layers by applying an ultraviolet laser to photo-curing resin.
Work size: X500 ×Y500 ×Z550 (mm)

New Businesses

Architectural Hardware

In recent years, there has been an increase in demand for optimized product design which takes into account higher performance, lighter weight, design, and other aspects, for steel cast components for construction, bridges, and other applications. Kochi Kigata Kogyo Co.,Ltd. can present final products (steel cast products) at the design consideration stage through application of our precision casting method (Digital Quick Casting) which eliminates the need for molds through use of laser molded products. This system is unique to our company and gives us a distinct advantage over other companies in not just higher strength and toughness through optimization, but also a significant speed advantage. We can also utilize our over 50 years of mold fabrication knowhow to fabricate steel casting molds, and deliver high quality, steel cast final products (mass production products) via overseas procurement through our Dalian, China Office. Come to us for one-stop fulfillment of all your design, development, prototyping, and procurement needs.

Examples Architectural hardware for an Osaka fashion brand building

Provides both visual appeal and strength

A world famous fashion brand opened a store in Osaka in February 2020. In order to achieve a unique, beautiful, full glass exterior, the architecture designer requested architectural hardware which had a clean and attractive casting surface, physical strength, hardness, and seismic resistance to fasten the plates of glass to each other. Because the architectural design exhibited the internal support structures holding up the glass, the project required not only functional beauty and utility, but also visual beauty.

Adding design details while being able to look at the actual products

We presented 3D printed three dimensional laser molded products made from drawing data to the customer during the deliberation stage, and had the customer inspect, revise, and verify the design of final products while looking at each which were accepted by the architecture designer. Because we were able to show the customer items which were the same shape and form as the actual products during the meetings, there were no later complaints, and the customer was very happy with the finished product.

Architectural hardware material characteristics

In general, hardware is made with SS material weld joined products, FCD and other material cast products, however our company recommends casting products with SCW material.
The reason is that a high degree of strength was required, whereas breaks could occur with FCD material, SCW material would not break, and while both are integrated cast products, SCW material can also be welded, making it easier to deal with on-site. In addition, we also proposed switching from SS material, which would require welding for some structures due to its linear design, to SCW material, which could be produced as integrated, single, curved pieces. Using laser molded products for structure changes allowed for more detailed and precise verification while carrying out work starting from the design stage.

Steel castings for welded structures (SCW) Rolled steel for standard structures (SS) Ductile iron castings (Ferrum Casting Ductile/FCD)
Design Higher degree of freedom Linear Higher degree of freedom
Welding ×
Breaking
Structure Integrated casting Weld joining Integrated casting

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