The manufacturing of aluminium die-cast products in Japan is steadily increasing. This is largely because of the high volume of automobile production in Japan.
Annually, Japan produces over 8 million vehicles. Meanwhile, aluminium die-cast products are used to produce different components of vehicles such as wiper, chassis, etc.
There are several aluminium die casting companies in Japan. However, in this article, I will show you the top 10 aluminium die casting manufacturers.
What are the top 10 aluminium die casting manufacturers in Japan?
The above is just a general list of the top 10 manufacturers. I will further explain each of these manufacturers in some details.
1. A.I.S Corporation
Location: Shizuoka
Company Type: Manufacturing
Year Founded: 1953
Main Products: Aluminium die casting
Other Products: Sand mold products, plastic products, etc.
This is a top Japanese aluminium die casting company that aims to be a self-sustaining manufacturer of high value-added die cast products. This company promotes integrated production of aluminium products from casting, cutting, painting and assembly.
Their customer base is largely in the automobile, motorcycle and marine industries. Their customers include Yamaha motor, Suzuki, Mets, NTN, etc.
The company’s headquarters is in Shizuoka, Japan. However, they also have an oversea base in Back Ninh province, Vietnam. They have a total of over 192 skilled employees.
For the automobile industries, their die-cast products include the telescopic, tilt steering mechanism, etc. For motorcycles, their products include the cover crank case, cover strainer, shaft drive, etc. For the marine industry, they produce the casing upper, casing lower, housing bearing, etc
A.I. S corporation is keen on their customers’ specifications. They design and develop their products largely with their customers’ inputs. Their production processes begin with prototyping. They have a production engineering section that plans, processes and makes prototypes per the individual customer’s specification.
This company also engage in product designs that incorporate the basic functions of market needs and customer requirements.
Cola Gokin Corporation
Location: Fukaya City
Company Type: Manufacturing
Year Founded: 1942
Main Products: Aluminium die casting
Other Products: Rubber metal fittings.
This company uses different materials in their business operations. They have a lineup of stretchable materials, hard materials and corrosion-resistant materials.
This company also has a swift production period. Generally, prototyping takes 3-4 days here. However, prototyping for mass production takes 6-8 weeks. They have squeeze die casting machines that are difficult to nest.
They also have ultra-high speed and ultra-low speed casting machines. They have an integrated production process. From casting to furnishing, processing, packaging, shipping, etc, all these take place in their factory.
This enterprise undertakes five stages of production in its production process. The first is mold designing. Here, the designer, mold engineer and the casting engineer would collaboratively study the mold. Secondly, they would thereafter manufacture high-precision molds using the latest machine tools and original technology.
Thirdly, they would inject molten aluminium alloy at high speed and high pressure into the mold attached to the casting machine. Fourthly, the die-cast products would be heat-treated, machined, surface-treated and assembled per the customer’s request.
The final production stage is the quality inspection stage. All these stages are to ensure quality outputs.
Largely, this company uses the squeeze die casting method in their operations. This involves molding molten aluminium at an ultra-low speed and pressing at high pressure. They have 2 squeeze die casting machines.
Cola Gokin Corporation has different high-end equipment and facilities. For example, they have 11 die casting machines of varying ability, ranging from 25t to 500t, 2 three-dimensional measuring devices, 1 x-ray inspection equipment, 1 component analyzer, 1 shape measuring instrument, etc.
They also have 2 dedicated processing machines, 2 washing machines, among others. Particularly, their products include engine mount bracket parts, anti-vibration rubber-metal fittings, pressure-resistant parts, undercarriage parts, etc.
Ahresty Corporation
Location: Toyohashi, Aichi
Company Type: Manufacturing
Year Founded: 1938
Main Products: Aluminium die casting.
Ahresty corporation has three business segments. These are the die casting segment, aluminium business segment and proprietary products business segment.
The die casting business segment produces and sells auto parts, industrial machinery parts, and general engine parts. The aluminium business segment oversees the smelting and sales of aluminium alloy ingots. The proprietary products business segment oversees marketing access floors and its accessories
This enterprise has unified global production bases across Japan, North America, and Asia. They prioritize excellent productions and have various first-rate equipment and machines.
They have over 100 large casting machines in Japan and across the globe. In every of their base, they have machining centres to enhance seamless production and processing of their die-cast products.
Ahresty Corporation produces almost 40 types of bullions ranging from die casting to aluminium alloy bullions for special applications.
This company has chemical analyzers for quality assurance and molten metal cleaning systems. They also have a jet cool system. This controls the cooling of the mold parts where seizure, sunk marks, and pressure leakage are likely to occur in the casting process.
This enterprise has a Technical centre. This is their centre for technological development. This centre also functions as a research centre for developing new materials and construction methods in aluminium die casting
Currently, the company manufactures die-cast products such as capacitors and step-up converter cases suitable for future automobiles with no engines.
Their main customer base includes Isuzu, Jatco, Suzuki, Subaru, Denso, Toyota motor corporation, Nissan, Honda, Yamaha, Mitsubishi Motors, Volkswagen, etc.
This company ensures eco-friendly business operations by imbibing recycling in its production process.
Iwaki Die Cast Co. Ltd
Location: Niiza
Company Type: Manufacturing
Year Founded: 1968
Main Products: Aluminium die casting
Other Products: Zinc die casting.
This is a leading Japanese aluminium die casting company. This enterprise is keen on customer satisfaction. They also have a detailed production process.
This company assigns a front-line design engineer to each customer. The designer listens to the customer’s requests and proposes quality and satisfactory die casting. They design their molds per each customer’s requests.
They also use leading-edge technology to propose a mold plan that is easy to cast. They manufacture molds using high-end equipment and high-precision machining. This company creates optimum machining process and machining data based on the 2D/3D data that meets the product requirements.
This enterprise has automated casting equipment, which boosts and expedites productivity. They use a spray robot to apply a mold release agent. To ensure exceptional output, they employ high-end equipment for x-ray inspection, gas amount analysis, strength test, etc.
Iwaki Die Cast Co. Ltd has a processing factory that processes its die-cast products. They also have an impregnation device that enables in-house processing of their productions. Their die-cast products are of high quality with less cavities and clean casting surface.
They carry on their die-casting activities with about 27 die casting machines (cold), 13 die casting machines (hot), 20 fully automatic ultra-high speed precision casting machines, 6 NC electric discharge machines, among others.
They also have 12 machining centres, 1 NC milling machine, 3 surface grinding machines, 6 polishing machines, two 3D printers, 3 degreasing devices, etc.
This company has several certifications such as ISO 14001, ISO 9001, among others.
Yutaka Die Casting
Location: Nagoya
Company Type: Manufacturing
Year Founded: 1959
Main Products: Aluminium die casting.
Yutaka die casting is another leading aluminium die casting company in Japan. This company has a wide range of die casting machines. These range from small 150t die casting machines to large 800t die casting machines. The 800t is for manufacturing large die-cast products.
This company prioritizes excellent output at competitive pricing. They achieve this by avoiding unnecessary movements of products during the production processes; also shortening the production cycle.
They also conduct their products’ post-processing indoors. They have various equipment such as 5 die casting machines, 1 melting furnace, 3 shot blasting machines, 1 two-dimensional coordinate measuring machine, 2 cranes, 1dryer, etc.
Their customer base spans the automobile and electronic industries, among others.
Sankyo Wash Metal Co. Ltd
Location: Takaoka City
Company Type: Manufacturing
Year Founded: 2008
Main Products: Aluminium die casting
Other Products: Sand die casting.
This is a front-line aluminium die casting company with state-of-the-art equipment and the latest technology. They have several machines such as 1 800-ton die machine, 3 500-ton machines, 1 350-ton machine, 2 250-ton machines, among others. They operate on fully automated die casting machines.
Their 800-ton die casting machines can handle both small-sized castings and medium-sized castings. They also have a low-pressure casting machine with a holding furnace of 500kg. Largely, they use the low-pressure casting method for manufacturing gas parts, handles, etc.
This enterprise also uses the cold chamber manufacturing method in its operations. Over 90% of their die-cast products are automobile-related parts. Their production processes are in the following stages: melting–hot water distribution–casting–finishing–shot blasting–inspection–processing–surface treatment–shipping.
In addition to their aluminium die casting department, Sankyo Wash Metal Co. Ltd also has a sand casting department. This employs the organic self-hardening casting method. Their major sand casting products are industrial robot-related parts, general machine parts, and electric power-related parts.
In terms of product weight, this company can handle large castings ranging from 1kg to approximately 250kg. To ensure high-quality productions, they have an inspection department. This department is equipped with high-end equipment and devices such as spectroscopic analyzers and 3D measuring instruments. They also have an x-ray transmission device for checking out any casting defect.
MIE Die Casting Industries Co. Ltd
Location: Inabe City
Company Type: Manufacturing
Year Founded: 1960
Main Products: Aluminium die casting.
This is a leading die casting company. They have a wide customer base such as Toya Denso Co., Mitsubishi electric co. Ltd, Matsusaka co. Ltd, etc. They have certifications such as the ISO 9001 certification, among others.
This company also has several high-end machines and facilities. They have 9 different casting machines of various capacities. Particularly, they have 2 800t casting machines. This company also has 18 NC lathes and various drilling machines/tappers.
They have integrated manufacturing processes too. Although aluminium die casting is largely used for bulk productions, this company has efficient process management to efficiently handle both small and large productions.
Izu Alloy Co. Ltd
Location: Shimoshiraiwa
Company Type: Manufacturing
Year Founded: 1958
Main Products: Aluminium die casting.
One of the hallmarks of this aluminium die casting company is that they undertake both small and large productions. This is unlike most die casting companies that undertake only large die casting. They also have an integrated production system that enables quick delivery of products.
This enterprise has state-of-the-art die casting machines that can handle wide range of sizes, as large as 5000g to 3g. They use all the ten types of JIS standard alloys in their operations. However, they can also propose original special materials too.
This company does not only process the die-cast products cast by their company, but also handles processes-only projects. They have a seamless delivery and bulk order system. They have a batch ordering system through an integrated production system and a network of partners.
They also produce a wide range of rotor parts in different sizes. These range from palm-sized ones to large ones with a size of 450mm and L750mm. Their production process involves casting, trimming, deburring, material inspection, machining, painting, and inspection.
Izu Alloy Co. Ltd has an in-house manufactured mold for trimming and removing unnecessary parts. They also use shot blasting machine in deburring. They have a large number of equipment such as 8 die casting machines of different capacities, 1 CNC lathe, 8 gas crucible furnaces, etc.
This enterprise also has 1 machining centre, 1 tapping centre, 2 radial drilling machines, 1 surface grinding machine, 2 general purpose milling cutters, 1 balancing machine, etc. Their products include intake fan cover, heat sink, drive shaft, explosion-proof case, etc
Alpha Corporation
Location: Kanagawa
Company Type: Manufacturing
Year Founded: 1923
Main Products: Aluminium die casting
Other Products: Zinc die casting.
This company produces high-performance products such as in-vehicle and residential electronic key systems, precision mechanical keys, etc. They use various technologies in their business operations. These include processing technology, automatic trimming and precision processing technology, and automatic assembly technology by robots.
They use the CAE (engineering support computer) to analyze the strength and rigidity of individual parts. They also use predictive technology such as mechanism analysis in producing automobile parts.
This company uses the latest CAD (design support computer) and further considers various production requirements. They perform advanced information processing in every production stage, from ordering to shipping.
For processing their die-cast products, they have CNC automatic lathe, key mountain cutting, key groove cutting, etc. This company also has an automatic line assembly for seamless assemblage of their products.
Alpha Corporation has an in-house automated assembly machine that utilises robots. They have a shutter assembly where they assemble cylinder shutters with an automatic machine. They also have a tumbler assembly with an automated machine for assembling the tumbler to the cylinder.
This enterprise has branches across North America, Asia and Europe.
Morizumi Die Cast Co. Ltd
Location: Kuguido
Company Type: Manufacturing
Year Founded: 1973
Main Products: Aluminium die casting.
This company produces hydraulic parts for automobiles, air tool parts that are resistant to pressure, and complex and precise digital camera parts.
They serve as a ‘one-stop’ company for die casting, from mold design to manufacturing and processing. They use high-end technology in their productions. They also ensure clean finishing by using deburring molded products with a shot blasting machine.
Their production processes involve mold designing, trial production, casting machining, finishing, surface treatments, painting, and testing.
Conclusion
In this article, I have explained the top 10 aluminium die casting companies in Japan. These companies include Morizumi Die Cast Co. Ltd, Izu Alloy Co. Ltd, Sankyo Wash Metal Co. Ltd, Iwaki Die Cast Co. Ltd, Ahresty corporation, among others. This knowledge would come in handy for you whenever you want to get your aluminium die-cast products from Japan.
