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.
Wooden molds for various ship hull construction cast parts / wooden molds for various machinery cast parts / pump parts / various 3 dimensional molded objects
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.
Agricultural machinery / industrial machinery / construction machinery / automotive machinery / design and art related
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.
We deliver to partner casting companies, who then carry out casting and
delivery products to agricultural machinery manufacturers
Digital Quick Casting
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.
Metal mold fabrication
Comprehensive cost reductions through vertical start-up using laser molding
A device which forms layers by applying an ultraviolet laser to photo-curing resin.
Work size: X500 ×Y500 ×Z550 (mm)
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.
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|
|Structure||Integrated casting||Weld joining||Integrated casting|