This week's Must See video and article comes from Modern Machine Shop. Gears are expensive parts to make in small quantities. This video from 3D Systems describes how just one gear—for an oil pump—was critical to overcoming a problem with excessive oil pressure in a Mitsubishi 4G63 race engine for a car run at over 185 mph.
English Racing of Camas, Washington, knew that a change in gear size might solve the problem, but the team didn’t know how to get this gear. The complex custom part would have been costly to machine as a one-off job, particularly since one-off prototypes would also be needed to test and refine the design.
Enter Metal Technology of Albany, Oregon. They proposed additive manufacturing instead, printing the part directly from the CAD model on its ProX 300 direct metal sintering machine. This video shows the part not only being additively manufactured in this way, but also functioning successfully at full speed within the engine:
Additive manufacturing once again solves issues previously too costly or too difficult to machine. Tip of the hat to HPI's Steve Murray for the heads-up about the video!
Hoosier Pattern recently hosted a joint dinner for the Geneva, Berne and Decatur Chambers of Commerce.
The event was held at our facility, and Keith Gerber (Owner, President) gave a short history of HPI and explanation of how products we make are used in foundries including cast parts.
Taylor Gage spoke about our Apprentice Program, Ryan Seddelmeyer discussed the hard tooling (subtractive manufacturing) side and Dave Rittmeyer explained the additive manufacturing side focusing on our 3D printer capabilities.
Tours of the entire plant were given by Dave, Ryan, Taylor and Todd Yoder. Fifty-two members of the combined Chambers were in attendance and as they say, a good time was had by all.
A few photos from the event:
In our never ending search for cool news about 3D printing and foundry related information, we have two sites for you to check out.
Spin Casting Miniature Soldiers
Our first site comes from Foundry Management & Technology Magazine, and it features a great video on spin casting miniature soldiers by an Australian entrepreneur who shows us what he's learned about melting, molding design and casting in the effort to start a new business. Check out the video:
A Free 3D Print File Health & Science Library from the National Institute of Health
Our second link comes from Live Science, a great website that spotlights new technology across all industries and disciplines. This article discusses a new website, launched by the National Institutes of Health:
People can now download, share and edit files for use in 3D printers from a new government website. The site has files that can be used to create models of anything from a human brain to deadly viruses.
The website, launched by the National Institutes of Health, is called the NIH 3D Print Exchange, and contains a library of files that a 3D printer can read and print. The files all relate to health and science; the available files include models of a human femur bone, the West Nile virus and a white matter section of the brain.
Users can also share their own files, edit exiting ones or create files using a tool that converts scientific data into ready-to-print 3D files.
Check out their video:
If you've been looking for files to 3D print your very own brain; this is for you. Enjoy!
Hoosier Pattern believes that a strong commitment to our local community is an essential part of our corporate philosophy.
After all, strong community ties make for strong business practices.
Hoosier Pattern and RH Warehouse recently donated funds to help with the purchase of graphing calculators for the math department at Bellmont High School.
Pictured are Keith Gerber, owner of Hoosier Pattern; Cindy DesJean, Bellmont High School math department chair (with one of the calculators); and Robin Gerber, owner of RH Warehouse.
These past few months have been busy, and June is no exception. We'll be at the 2014 RAPID Conference and Expo June 9-12 in Detroit. RAPID is a great destination for learning, networking, and growing your business with additive manufacturing and 3D printing.
Dave Rittmeyer and Steve Murray are attending and, to celebrate the event, we have a few free tickets we're giving away to get into the Exhibition Hall, valued at $75 each.
They're available to you on a first-come, first served basis. If you want one, call (260) 724-9430, and we'll make arrangements to get one to you.
And if you're attending, be sure to visit us at booth # 1627!
HPI Case Study
Client: OK Foundry, Richmond VA
End User: Oswalds Mill Audio
Product: Cast Iron Open Baffle Loudspeaker
OK Foundry, an iron foundry based in Richmond VA well known for their architectural castings, was recently involved in creating a very unusual end product: a large, freestanding open baffle speakers made of gray iron. The dimensions for this one-of-a-kind set of speakers were 34.6" x 51.1" x 3" each and weigh around 330 pounds each.
OK Foundry’s client, Oswalds Mill Audio (ΩMA), is a unique audio company based in DUMBO, Brooklyn. Their design philosophy states, “Instead of following current trends and embracing so called ‘cutting edge technology’ we take a look back.” All of their hand made audio equipment is made in Pennsylvania out of local hardwoods, slate and steel. In addition to their extremely high-end products having a retro appearance to them, they also embrace audio fidelity concepts used in cinemas and studios in the 1930's through the 1950's.
ΩMA had created a design for a large open baffle loudspeaker system cast from iron. Because of the complexity of the design, the foundry determined that the 3D sand mold made more sense than the price for tooling for essentially a “one-off” casting. Also, the tooling to extract the mold would have compromised the design and because HPI was able to print the right and left sand molds there was no need to individually tool the same set.
HPI created the complex mold utilizing our ExOne® 3D Sand Printer and OK Foundry was able to pour and create a remarkable product which will be on display at the International Contemporary Furniture Fair, May 17th-20th at New York City’s Jacob Javits Convention Center.
Photographer Cynthia van Elk has provided some photos capturing the whole process of creating the speaker from sand mold to end product.
HPI takes pride in being able to provide a wide range of solutions to complex design issues facing foundries and fabricators today.
HPI recently attended the 118th Metalcasting Congress held in Schaumberg, IL. April 8-11th.
We were among the 2200 registrants who participated in North America's largest event for the foundry industry. There were more than 250 exhibitors of which we were proud to be a part of. Thanks to all the people who stopped by the HPI booth and we'll see you next year.
For a review of the event and information about next year's Congress, visit their website.
HPI offered all the attendees at the recent 118th Metalcasting Congress an opportunity to win a handsome bronze casting of our iconic "Pouring Man." The casting is from a sand mold created by our very own S-Max™ 3D printer. Seen in the photo are (left) HPI's Nate Chavarria, Lead CAD Designer, presenting the cast to (right) Kyle Patterson.
Here's what Kyle had to say: "First off, thank you for the pouring man cast model. I am a junior majoring in Manufacturing Technology at the University of Northern Iowa with an emphasis in Metalcasting and plan to graduate May 2015. I certainly do plan to work in the metalcasting field after graduation, but as of now I do not know in what area of the field since there is such a wide variety of options. I am also the president of our AFS student chapter."
Thanks to Kyle and all the folks who stopped by our booth at The Congress. See you next year!
The Super Mileage Challenge is held annually by the Indiana Math Science Technology and Engineering Alliance. It challenges teams to build a one-person, fuel efficient vehicle based around a one-cylinder, four-cycle engine. Last semester Catherine Sondgerath's Bellmont High School students spent 5-6 weeks developing a detailed design proposal that included calculations for rolling friction, aerodynamic drag, and cornering forces. Their design concept is based on having a light weight, low friction vehicle that is aerodynamic and evenly distributes weight between its three tires. This year the challenge is being held on April 28th at the Lucas Oil Raceway.
Hoosier Pattern and Goldshield helped by taking the 3D CAD model the students created, made a mold and made their fiberglass body. Hoosier Pattern also helped with making some of the custom parts. Money received from the Adams County Community foundation was used to help buy the engine, spare parts and tires. Bellmont High School also received donations from K-K Tool and Pretzels Inc. This is Catherine and the students' first year competing in the competition. She had this to say about the project, "It has been a great learning experience and challenge which we have all enjoyed. We greatly appreciate all of the community support as this project would have been impossible without our sponsors."
Here are the names of everyone in the photos:
Left to right: Back row: Catherine Sondgerath Bellmont HS teacher, HPI's Phillip Bauman, Ryan Seddelmeyer, and Todd Yoder. Jeff Newport, Tom Westerlund, Jeff Condon, Brandon Brown, Korbin Marbaugh, Jerry Hart, Drake Gillespie, Alec Grose, Denver Smith, Alex Johnson. Front row: Justin Blanford, Dee Girod, Mason Averill, Mason Mendez, Parker Burkhalter, Austin Garrison, Spencer Morris
Hoosier Pattern's Dave Rittmeyer will be on the "Molding Methods & Materials" panel which is part of the "Additive Manufacturing for Metal Casting Applications" presentation at the 118th Metalcasting Congress. The panel will be discussing the state of 3D printings technology, review basic design freedom and discuss current programs to utilize this technology. The panel meets on Wed. April 9th at The Renaissance Hotel, Schaumberg, IL. Dave will be presenting Case Studies in Printing Cores and Molds.