Foam pattern

●Full‑mold casting replaces traditional wooden patterns with foam patterns
・Production process
Pattern fabrication → Setting in the mold frame → Sand packing → Metal pouring → Final casting

・Merits
1) Significant reduction in lead time
2) Capability to produce complex shapes
3) Flexible response to design changes
4)Reduction in total cost

・Materials
FC, FCD, cast iron, cast steel

Metal pouring

●Kimura Foundry’s Additional Strengths

・Size : Maximum dimensions: 8,200 mm (length) × 2,500 mm (height)
・Unit weight: 1 kg to 40 tons
・Machining: Integrated machining or single‑process machining, Workpiece size: from palm‑sized to 10 meters, Suitable for prototypes to mass production
・Sand 3D Printer: Minimum wall thickness 2 mm, Supports AC‑based materials as well
・Reverse Engineering:
・Custom Wear‑Resistant Castings & Piping

Non‑contact 3D scanner

●Craftsmanship forged through full‑mold casting

・3D Data Creation: Converting sketches, photos, or even cases with no existing data into 3D models,
utilizing ATOS and 3D scanning technologies
・Size: Foam patterns can exceed 10 meters, and cast‑iron products can be produced up to 30 tons
・Urethane Coating: Enhances strength and prevents damage and deterioration
・Applications: 3D signage, mock‑ups, and more

●Strengths and Benefits of Kimura’s Reverse Engineering

・Strengths: Solid modeling, casting production, photography, and on‑site measurement

Benefits:
1) Creation of 3D data identical to the actual object, plus cast‑iron reproduction
2) Usable for structural analysis
3) Comparison between product and drawings
4) Converting wooden patterns, metal molds, and sand molds into 3D data to reduce storage needs
5) 3D data archiving of artworks and cultural assets
6) Capturing and preserving craftsmen’s skills in 3D data

●Kimura Foundry’s Unique SDGs Initiatives

Maximizing the Use of Scrap Materials: Remaining expanded polystyrene waste is compacted in‑house and transferred to recycling companies

・Use of the “EG Runner” gating system: casting waste after pouring is extremely minimal
・Extensive use of manipulators: significantly reduces dust and noise
・Of approximately 120 female employees, 80% are on-site technical staff