Rapid, high-quality production to demanding standards.

Kyowa is a one-stop-shop-solutions resource for all your prototyping and low-volume production needs. Whether you need one unit or 1000, our rapid prototyping and design process allows us to deliver precision-manufactured components of the highest-quality rapidly and cost-effectively.

We work from the original designs created by your design engineers and precisely manufacture components that are functional, durable, highly reliable, and as light as possible.

Prototype Development and Manufacturing

Kyowa handles a wide range of prototyping needs – we specialize in complex, time-sensitive projects that require the utmost precision. Our experienced team of engineers and craftsmen has worked on countless projects over many years – ranging from compressor parts to the engine cylinder block for the Formula 1 racer.

We have developed a careful and highly efficient process that can take a complicated product from development, through prototyping, finishing and inspection to deliver unsurpassed quality, while saving weeks of production time in comparison to ordinary suppliers.

Typical components include:

  • Cylinder blocks
  • Cylinder heads
  • Engine parts
  • Transmission cases
  • Motor cases
  • Rocket & aircraft parts
  • Semiconductors & LCDs

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Kyowa delivers low volume production runs with the same standards of quality, timeliness and efficiency as our prototypes.

Low Volume Production

Kyowa delivers low volume production runs with the same standards of exceptional quality, timeliness and efficiency as our prototypes. We have a long history of producing parts for the auto, aerospace, recreational vehicle, and other industries, as well as car air conditioners, IT-related components.

Our many years of mass production experience, as well as our proprietary technology based on our QCD system allow us to deliver every part with great precision, efficiency and uncompromising quality.

The repeatability of our process stems from our highly automated system that starts with our Direct Numerical Control and our integrated production and finishing systems.

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We use Japan’s most advanced sand molding technology and highly skilled craftsmanship to produce sand casting products down to 1mm wall-thickness that are superior to die casting in quality.

Casting

Kyowa works closely with our casting partner to prepare patterns and molds, conduct trial castings, and complete full-scale casting and low volume production in as short as 5 weeks. Our approach brings together Japan’s most advanced sand molding technology and highly skilled craftsmanship to produce sand casting products that are superior to die casting in quality. We draw on 70 years of collective experience in the craftsmanship of non-ferrous metals, and exceptional quality control systems.

  • Wall thickness to as low as 1 mm
  • Wall thickness clearance to +/- 0.3 mm
  • Outline clearance +/- 0.35 mm
  • Complex shapes
Case Study: Inverter Case

The inverter case prototype developed by Kyowa for Japan’s first eco-car (highly fuel efficient vehicles) received strong praise for its performance and served as the basis for the final, mass-production design adopted by the manufacturer. Key attributes of the design that indicate our leading-edge casting capabilities include:

  • Ultra-fine fin forming (casting of wave fin and pin fin shapes)
  • General thickness: 2.0-2.5mm
  • Thickness tolerance: +/- 0.3mm
  • Waterway dimensional tolerance CT5 equivalent
  • Material: High thermal conductivity material casting allowed
Case Study: FF, FR Transmission Case

Kyowa proposed that a leading manufacturer change its manufacturing process for spline shapes from its traditional EDM (electro-discharge machining) technique to a casting process. Based upon adoption of our recommendation, the manufacturer was able to significantly reduce costs and lead-time of its production process. Product highlights include:

  • Spline shape: Equivalent accuracy to die-cast products
  • General wall thickness: 1.8-3.5 mm
  • Thickness tolerance: +/- 0.3mm
  • Material: Aluminum sleeve casting

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Our state-of- the-art facilities, a well-established QCD system and decades of experience allow us to complete a full range of complex machining assignments from start to finish in very rapid cycles.

Full-Service Machining

Kyowa has a full-service machining capability, featuring more than 70 machine tools, including 15 different 5-axis simultaneous control machining centers, which allows us to tackle the most complex machining tasks in a minimum amount of time.

Our integrated process allows us to reduce cost and delivery time significantly. We have an engineering lab with the latest CAD software, connected through Direct Numerical Control (DNC) systems to our machining facilities. After machining, our prototypes and components go to inspection and finishing.

We handle a full-range of machining tasks on site, including:

  • Stamping
  • Metal Printing
  • Boring
  • Honing
  • Multi-axis simultaneous machining
  • Finishing
  • Weldment
  • Inspection

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