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Latest update: 30/09/2021 18:41:56

Umezawa cyuko Co.,Ltd

We will help reduce the cost of casting production by utilizing styrene foam models.

Our company is a manufacturer of castings for machinery and ornamental uses. We manufacture styrene foam models in-house, helping reduce costs for high-mix, small-lot products such as made-to-order products and prototypes. There are no restrictions on the size or weight we can handle. We create 3D data from 2D CAD drawings.

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Sales Pitch

Data Creation
Data creation with 3D CAD
For press dies, we can create 3D data from 2D CAD drawings if you have them. 3D data can also be made from paper drawings.

Data creation when no drawing is available
Please consult with us as we can trace the actual product for casting.
Modeling Technology
Flexible because we produce styrene foam models in-house
They can be produced in any form.
The casting method using a styrene foam model (FMC) is particularly cost-effective for small-lot production of castings with complex shapes.
Suitable for made-to-order products and prototypes.
We can meet a variety of customer needs because we manufacture styrene foam models in-house.

・Advantages of styrene foam models (FMC)
-It allows cost reduction for high-mix, small-lot production of built-to-order products and prototypes.
-Depending on the quantity, a wooden model may be more beneficial.
-Both industrial machines made by the loose piece casting method and press molds made by the full mold casting method can benefit from this method.

・Available size and shape
-There are no limits to the size and weight of the product. We can make it in basically any form.
-It can be produced if you have drawing data (either 2D or 3D, or even paper drawings will do).

・Data receipt
-We will accept no matter the case.
-Even if drawings are unavailable, we can still make castings by tracing the actual product. Please consult with us.

・Manufacturing styrene foam models from 3D CAD drawings
For press dies: 2D CAD drawing -> 3D CAD drawing recreated in our company -> Produce styrene foam model
All the processes up to the finished styrene foam model are conducted in-house. 
3D CAD -> NC -> Finished model -> Casting -> Cast product
Drawing -> Model manufactured manually -> Finished model -> Casting -> Cast product

・Production period
-Delivery time varies depending on the shape.
-The product can be made as quickly as half a day since we make the styrene foam model in-house.
-Some shapes take longer than ten days. Please consult us from the inquiry/technical consultation page.

・We also make ornamental styrene foam models.
Aside from casting models, we accept orders for models for ornamental or other purposes.
Loose Piece Casting Method
Possible casting range is 1 to 2,000 kg. We conduct model production, casting, and machining internally.
With the loose piece casting method, a model (wooden or styrene foam model) is placed in a metal frame, and a sand mold is made.
 After removing the model from the mold and setting the loose piece to match the mold, molten metal is poured into the mold.
The casting is removed from the sand and finished.

・Castings made by our company
-Size: 1 to 2,000 kg
-Height and width: Contact us as it depends on the shape. We can make long castings and partially high castings.
-In-house mold sizes: Multiple sizes are available within the range of 550 mm x 550 mm (min.) and 2400 mm x 2400 mm (max.)
-Material: FC200 to 350 (ordinary cast iron) and FCD400 to 700 (ductile cast iron)
-Delivery time: Please contact us as it varies depending on the size, shape, and material.

・Model production and machining can be conducted in-house.
-We conduct styrene foam model production, primary casting processing, metal parts processing, and machining internally.
-We are confident in our processing techniques.
Full-mold Casting Method
In-house production of styrene foam models at low cost, even for complex shapes that are difficult to produce by die casting: In the full mold casting method, a model (vanishing model) is made of styrene foam and placed in a mold. It is a method of manufacturing castings by replacing the model with molten metal during pouring. This is why it is also called the vanishing model casting method. It does not require cores, unlike the die casting method, allowing shorter delivery times and cost reductions. The full mold casting method is primarily used in the field of press mold materials.

Advantages of the full mold casting method
Enables shorter delivery times and cost reductions for casting: Because it is coreless, the time-consuming process of the model, coating, drying, molding, and casting can be eliminated. Reducing manufacturing processes allows for shorter delivery times and cost reductions. Complex shapes, which are difficult to achieve with die casting, can be cast at low cost. Since cores do not need to be combined and the desired shape is made directly from the styrene foam model, it is possible to produce castings with complex shapes at low cost.

Disadvantages of the full mold casting method
Residue on the casting surface is an issue. Styrene foam cinders tend to remain on the casting surface as residue. Residue control is an issue because it is a new technology.

We make our own styrene foam models
Other companies often outsource styrene foam models, but we manufacture them in-house. (We can supply the models.)
Trial Casting (single product)
Use of styrene foam models reduces costs significantly. There are also many advantages in terms of delivery time.
When using styrene foam models to produce prototypes, you can reduce the model production cost to a fraction of the cost of wooden molds. Another advantage of styrene foam is that it has excellent processability and is easy to change in shape. It also shortens the delivery time. Our company can produce FC (cast iron) and FCD (ductile iron) castings.

・The model production cost is about 1/5 of that of a wooden model.
When using styrene foam models, you can reduce the model production cost to 1/5 of the cost of wooden molds for up to five models. However, we will propose a wooden model if it is less costly due to the shape and quantity. Depending on the amount, the wooden model may become the customer's fixed asset, whereas the styrene foam model is regarded as consumable, which is also an advantage.

・Shorter delivery time
Since styrene foam models can be manufactured in-house, we can make minor adjustments and shorten the delivery time.

・The more complex the shape, the greater the cost advantage.
Styrene foam has excellent processability, so in prototypes that require frequent shape changes, the more changes you make, the more cost benefits you get.

・In addition to prototypes, single products and small lots are also possible.
By taking advantage of the above merits, we can use the method to produce single products and small-lot items.
Processing Technology
Integrated production of metal parts and machining in house
We can provide one-stop services from the production of styrene foam models to casting, primary processing, and finished processing. Our strength is that we can work flexibly because the products are entirely manufactured in-house.

Primary processing
We can test the quality of the products before delivery. Since we deliver the products just before the final processing, we can reduce the number of quality checks for you. You can also use our bottom processing and nothing else. We often perform bottom processing for press dies.

Finishing
We process the metal parts and machining until they are finished (products as per the drawing that can be used as finished parts).

This company is recommended by the following support organizations.

Kanto Head Office, SMRJ
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