Cast products

Casting involves melting a metal material and pouring it into a mold where it is cooled and solidified to create a product with a shape suitable for a particular purpose. Iron, aluminum alloy, copper, brass, and other metals are used as materials. Plastics, rubber, and glass are also used. Molten metal is called “melt” and the die used for casting is called a “mold.” A mold is created on the basis of a product model made of wood, plaster, or metal. Casting also refers to a product made by casting. Casting can mass-produce even products having complicated shapes and large sizes. This is one of the processing technologies that are essential for Monozukuri (Manufacturing) craftsmanship. There are a great many metal products made by casting, from daily necessities and industrial products to arts and crafts. An upright cylindrical furnace called a cupola furnace is used to melt iron. The 1962 film “Foundry Town” (Cupola no aru machi), starring the actress Sayuri Yoshinaga, is set in Kawaguchi City, Saitama Prefecture.


Cast productsのcorporations list

WATANABE FACTORY Ltd. (Yamagata Prefecture)

Manufacturing the high rigidity pulley systems that support the elevator at Tokyo Skytree.

Based in the engineering skill we have accumulated through the manufacturing of elevator sheaves (pulleys), we possess a great deal of knowledge related to high rigidity, abrasion and pressure resistant cast iron components, as well as our own proprietary materials. We are currently developing new casting materials with the same properties as pre-hardened steel.

Products & Technologies Catalogs 1
OKAMOTO Co., Ltd. (Gifu Prefecture)

We have an integrated manufacturing structure that encompasses everything from materials to design, processing, surface treatment, and assembly, with our casting technology in its center.

We are a casting manufacturer founded in 1560. We have been working on "casting manufacturing" for over 5 centuries with new technologies and perspectives. We have an integrated manufacturing structure that encompasses everything from materials to design, processing, surface treatment, and assembly, with various equipment including a machining center, complex NC lathe, grinding machine, and wire discharge processing machine. Our original materials out of our highly advanced casting processes are under the spotlight with their superior wear and corrosion resistance and durability. We have an excellent track record with major domestic as well as overseas companies.

Products & Technologies Catalogs 2
NAKAKIN CO.,LTD (Osaka Prefecture)

Our aluminum engine parts with a hollow complicated shape have contributed to weight reduction of automobile engines.

Our main businesses are automobile engines and pumps. Our auto engine section has developed aluminum casting parts, and an aluminum engine part with a hollow complicated shape that is as thin as 3mm, which is contributing to weight reduction of the engines. We are also striving towards higher quality in traceability system s, non destructive inspection by X-ray CT, and a three-dimensional measurement. Our pump section is producing rotary pumps, successfully minimizing the clearance in the pumps.

Products & Technologies Movies Catalogs 1
Hamakita Kogyo Co., Ltd. (Shizuoka Prefecture)

We developed the environmentally friendly ultra-high-yield casting method, which reduces the amount of molten metal by 25%.

Our company manufactures alloy cast iron for a wide range of industrial fields. These include parts for 2-wheeled and 4-wheeled vehicles, parts for industrial machinery, and construction material. We particularly excel at producing small to mid-sized parts weighing 0.1 kg to 15 kg. Our recent efforts are focused on developing new technologies and new manufacturing methods. These include our ultra-high-yield method, which is an environmentally friendly casting method that reduces the amount of molten metal by 25%, which is a world-first.

Products & Technologies

Cast productsの活用事例集

High rigidity, abrasion resistant cast iron materials

WATANABE FACTORY Ltd.
Elevator sheaves used in Skytree and other high rise buildings

Pre-hardened casting material for use in metal molds

WATANABE FACTORY Ltd.
High rigidity elevator sheave (450 HBW) Metal molds for plastic injection casting (core type), distribution element for die cast manufacturing

Super Metal Series ECORR, STARK, RADMn

OKAMOTO Co., Ltd.
Thread rolling die (STARK) Powder and granular material volumetric feeder (ECORR): We have changed the material of the metal touch sliding area to ECORR, which has improved wear resistance performance.

OLS processing

OKAMOTO Co., Ltd.
The sliding parts in a metal mold have been treated by OLS processing.

Sanitary rotary pumps

NAKAKIN CO.,LTD
Supplies to almost all top dairies and drink companies domestically in the field of food. Many users adopt our products with 100% share. Our pump with high precision and safety is adopted to all process of compounding, sterilization and filling where the severe production standard is applied.

Ultra-high-yield method: an environmentally friendly casting method

Hamakita Kogyo Co., Ltd.
We make camshafts for 2-wheeled vehicles, 4-wheeled vehicles, ATV, and general engines. They have been adopted by Yamaha Motor, Yamaha Motor Power Products, Aisin Takaoka, Kawasaki Heavy Industries, Hitachi High Technologies, and other customers. Our ultra-high-yield environmentally friendly casting method is used in the manufacturing process. Our camshafts are cast using an environmentally friendly sand casting method. Our FCD high-frequency quenching camshaft has reduced ferrite and enhanced hardenability due to the use of a dedicated camshaft material. We also manufacture irregularly shaped hollow camshafts using a core to reduce the weight of the casting material.

Cast productsの用途提案集

High rigidity, abrasion resistant cast iron materials

WATANABE FACTORY Ltd.
Best used for hydraulics and air pressure systems parts which require airtight performance. Best used for parts which are especially in need of abrasion resistance.

Pre-hardened casting material for use in metal molds

WATANABE FACTORY Ltd.
When manufacturing plastic molded products, this product can be nested and used as a core when slow coagulation is hurting productivity or when manufacturing products for which temperature regulation is difficult, resulting in deformation issues.

Super Metal Series ECORR, STARK, RADMn

OKAMOTO Co., Ltd.
Applications which require both corrosion resistance and wear resistance, such as food-processing machinery (powder kneading mixers and valves, and feed chopping blades, etc.) Applications which require both corrosion resistance and wear resistance, such as food-processing machinery (powder kneading mixers and valves, and feed chopping blades, etc.)

OLS processing

OKAMOTO Co., Ltd.
This is effective for sliding parts which is are hard to grease on a daily basis and as lubrication for "sliding surfaces with less space" for sliding parts such as linear guides.

Sanitary rotary pumps

NAKAKIN CO.,LTD
This is also used for the chemical and pharmaceutical products with having high sanitary characteristic being finished under Ra 0.6 since all the wetted parts furnished are the make of SUS316L, SCS16 and the Nakamura metal which is the own development of the Company. And moreover, the traceability demanded by GMP and so on are accepted with satisfaction by users since the material casting is also manufactured within our plant. Since it is contactless, no contamination occurs by the abrasion of wetted parts. With this characteristic, it is used for the liquid feeding for the food and pharmaceutical purposes where requires highly sanitary treatment and the contamination is not allowed absolutely. One of the example is the successful use for the liquid feeding of the cathode materials slurry liquid as the raw material of fuel cell.

Ultra-high-yield method: an environmentally friendly casting method

Hamakita Kogyo Co., Ltd.
Our cast parts are recommended for general and industrial machinery parts. The amount of molten metal can be reduced by 25% using the environmentally friendly ultra-high-yield casting method we developed in-house. We manufacture cast parts for various fields in addition to cast parts for construction and agricultural machinery. We are particularly confident about small to mid-sized parts weighing 0.1 kg to 15 kg. Our company can respond to various customer requests. This is done by utilizing the experience and know-how that we have accumulated since our establishment in 1967. Please do not hesitate to consult us. We will continue to enhance our company’s technological strength. We will continue to provide products and technology that always surpass the customer’s expectations even though the needs for high quality and energy conservation are being heightened.

Cast productsの動画集

NAKAKIN CO.,LTD

Our aluminum engine parts with a hollow complicated shape have contributed to weight reduction of automobile engines.
Our main businesses are automobile engines and pumps. Our auto engine section has developed aluminum casting parts, and an aluminum engine part with a hollow complicated shape that is as thin as 3mm, which is contributing to weight reduction of the engines. We are also striving towards higher quality in traceability system s, non destructive inspection by X-ray CT, and a three-dimensional measurement. Our pump section is producing rotary pumps, successfully minimizing the clearance in the pumps.

Cast productsのproducts list

High rigidity, abrasion resistant cast iron materialsWATANABE FACTORY Ltd.

Our proprietary cast iron materials exceed JIS standards for hardness and possesses excellent abrasion resistance.

This material has a higher level of rigidity than FC300, FCD800, and other JIS standards specifications. Best used for sliding components and other parts which require abrasion resistance. Hardness can be specified in the range of 300 – 500 HBW.

Subimages 1 Purposes 2 Examples 1

Pre-hardened casting material for use in metal moldsWATANABE FACTORY Ltd.

Cast iron and cast steel materials with comparable properties to traditional pre-hardened steel

Although this is a cast material, it is a material which possesses properties equivalent to steel typically used for metal mold manufacturing. When working with processes such as plastic molding, temperature control of the metal molds can affect productivity a great deal, but because these are cast materials, they can fitted in advance with internal temperature regulating piping. Useful for metal molds which cannot easily be fitted with temperature regulating pipes.

Subimages 1 Catalogs 1 Purposes 1 Examples 3

Super Metal Series ECORR, STARK, RADMnOKAMOTO Co., Ltd.

Composite high functional metals which have properties such as "wear resistance", "corrosion resistance", and "high toughness

High function composite metal is made from uniformly dispersing vanadium carbon with a very high degree of hardness throughout the metal base plate using advanced casting processes. These are our new and original materials, which have multiple characteristics such as excellent wear resistance, a high degree of toughness, and corrosion resistance. We have developed a series of 3 products which have different characteristics and thus meet our customers' different needs.
- ECORR: excellent corrosion resistance + wear resistance materials + high toughness
- STARK: excellent wear resistance + high toughness
- RADMn: excellent wear resistance + non-magnetic + high toughness

Subimages 1 Catalogs 1 Purposes 2 Examples 2

OLS processingOKAMOTO Co., Ltd.

This is a process which inserts a solid lubricant mainly consisting of molybdenum disulfide into a metal surface.

OLS processing carries out processing on holes and channels on parts such as metal plates and rails, and lays a solid lubricant which uses molybdenum disulfide as the main constituent under the processed part. This prevents "galling" and "seizing" on sliding parts between metals. This is mainly adopted in guide parts for press mold forming metal molds and industrial machines.

Subimages 1 Catalogs 1 Purposes 1 Examples 1

Sanitary rotary pumpsNAKAKIN CO.,LTD

Rotary pumps for food , chemical, and pharmaceutical products that offer world-class quality and performance.

Sanitary rotary pumps are non-contact pumps with 70µ clearance between rotor and casing (the pump case). Since it is contactless, there occurs no contamination by the abrasion of the wetted parts. With this characteristic, these pumps are used by 20,000 end-users from food, pharmaceutical, and other industries. By adopting our patented Nakamura metal No.3, low expansion rate special alloy, we have achieved the micron level clearance with safety characteristics of non-contact pumps and high performance that is comparable to that of contact types.

Subimages 5 Catalogs 1 Purposes 2 Examples 1

Ultra-high-yield method: an environmentally friendly casting methodHamakita Kogyo Co., Ltd.

This casting method reduces the amount of melted molten metal by 25% for the first time in the world.

We developed the world’s first environmentally friendly casting method. The ultra-high-yield method reduces the amount of melted molten metal by 25%. Compressed air and sand are blown into the gate and path after the reduced molten metal is poured, unlike conventional gravity casting. This results in a reduction of molten metal by the amount necessary for the gate and path, and so the energy necessary for casting is significantly reduced. We can say that this is a next-generation casting method that overturns conventional casting practices. The workflow in the ultra-high-yield method is as follows.
(1) Pour molten metal only for the product and the riser part.
(2) Fill the product and the riser with molten metal, using compressed air, and fill the path with sand.
(3) The molten metal in the product and path coagulates.
This casting method is expected to bring about a huge energy conservation effect if it spreads both in Japan and overseas. The ultra-high-yield method is a result of the experience and know-how that we have accumulated since our establishment in 1967.

Subimages 1 Purposes 1 Examples 1