November 2018 News

21st Anniversary Printed Sand Sale!

Hoosier Pattern celebrated 21 years as a company on November 10th and although there are multiple contributors to how we got here, it wouldn’t be possible without quality customers and loyal partnerships. Hoosier is extending the anniversary celebration to include customers by having an anniversary sale on 3D sand printed projects. 15% off will be given to projects that are printed using silica sand, our standard 2 week lead time and with a minimum printing order of $1000. This sale does not include CAD and engineering time, specialty media or expedited orders.

 

Now is the perfect opportunity to get those end of year projects started. Purchase orders must be received between November 16th and December 16th to qualify for this promotion. To request a quote or place an order contact orders@hoosierpattern.com or upload your files through our secure web portal: https://hoosierpattern.com/send-a-file

 

Best Uses for 3D Printing

Prototyping

Sand printed molds and cores can only be used once, which makes them the perfect option for prototypes. If you have more than one design for a potential part, prototyping can be used to determine which mold or casting is the best option. All of the designs can be sand printed quickly, simultaneously, and at a cheaper cost. Each mold will be individually identified, which prevents confusion when it reaches the customer. Since all 3D printed sand parts start with a CAD file, parts can also easily be tweaked and re-printed.

Low Volume Production

The term “low volume” can be defined differently by every company. We define “low volume” as anywhere from 10-500 units per year. It may not be the best choice for a company to invest in the traditional tooling process if a part will only be used for a short amount of time. Sand printing may be the best option for smaller or temporary projects.

Strict Deadlines

Sand printing is the best choice when projects require a fast turnaround. At Hoosier Pattern, many of our employees have a foundry background, so we understand how critical deadlines can be. Our standard turnaround time for 3D sand prints is 10 days. This is 10 days from the time the order is placed to the time the project will be back on the foundry floor.

Our 10-day turnaround time has changed the game for many of our customers. In the past, it could have taken several months for a tool to be completed and reach a foundry. After we receive the CAD file, we plug it into a job box. Our job box is roughly the size of an average refrigerator and takes 20-22 hours to print. Because this turnaround time is so fast, we are sometimes able to do rush orders. Our employees do everything they can to ensure a customer has their product when they need it.

Case Study: Dalton Foundry

Foundry Uses HPI's 3D Sand Printer To Make Deadline

Dalton Foundry of Warsaw, Indiana had a case to solve for a customer—and time was running out.

Client: Dalton Foundry

Product: Gear Case Housing

Batch Size: Prototype (20)

Product Size: 29" x 26" x 12"

Material Cast: Class 30 Gray Iron

Traditional Method Cost & Timeframe: 8 Weeks at $13,000.00

HPI's 3D Sand Printing Method Cost & Timeframe: 1 Week at $1,165.00

Product Overview

The problem part in question was a section of 443-pound gray iron gear case. The corners—or ribs—in several points were cracking during the casting process. The gear case cover housing is used in industrial air compressors found at work sites to generate air and power. This was a prototype casting that was scheduled to go into production but couldn't be moved forward in the process if the end result was cracked.

Client Challenges

Dalton attempted several different processes and gating-related modifications, but a crack kept appearing. Because of the location and nature of the crack, Dalton employees thought the cracking may be a result of stress during the solidification process. Repeated simulations were run referencing the original design, which led to the conclusion that the defects were related to the design itself. The stress in the casting was the result of the original design’s base being so large that it took much longer to solidify than the other areas of the casting.

Our Solution

A plan was put in place to cut the metal tooling again, but the redesign of the part took much longer than expected. Now time was becoming critical to the project. It was at this point that Dalton turned to Hoosier Pattern and opted to make the cores using our 3D sand printer. In this specific case, Dalton saw the 3D printer could print directly from the CAD file without the upfront tooling cost—this was groundbreaking, especially with a prototype piece that had a history of cracking. With our 3D sand printing capabilities, design changes could be made quickly and a new core could be printed and pour-ready within days.

Results & Conclusion

The first pour using the 3D printed sand core was a success—no defects or cracks were found on the prototype. Twenty additional castings were needed and all of them were poured flawlessly using the 3D printed cores. Not only were there zero defects, but all the prototypes were made in a few days rather an in the few weeks a traditional tooling method would have required.

Our Competitive Advantage

Hoosier Pattern works very closely with all of our customers, enabling our designers to make changes on the fly to keep projects moving forward and meet customers’ needs and deadlines. Hoosier Pattern's 3D sand printer operation is effective and more practical for quick turnaround times.

"Our customer was up against the wall needing parts. We were aware of 3D printing and that a printed core would be turned in less than a week. The success of the part required two leaps of technological faith: stress simulation and using printed cores. Both worked out great" - Rob Burita, Tooling Engineer, Dalton Foundry

Case Study: Strand Design

Product Development and Prototypes On A Time Constraint

Chicago designers get help with redesign, a prototype, and tooling for a project all in one place.

Client: Strand Design

Product: Fourneau Bread Oven

Batch Size: Prototype

Material Cast: Gray Iron

Traditional Method Timeframe: 2-3 Weeks

HPI's 3D Sand Printing Method Timeframe: 1 week

Product Overview

The Fourneau Oven is a cast iron container that goes inside of an oven. It is designed to make bread using the “no knead method” made famous by Mark Bittman of The New York Times. The device's walls heat the dough evenly and the enclosed cooking space traps the steam from the baking bread, creating a crispy golden crust.

Client Challenges

Strand Design came to HPI more than once with multiple oven design molds that weren't possible due to the way it was designed. The designers asked HPI to re-engineer the molds to add proper gating and risers, allowing it to be completed within a short time span. Once the design was tested, it was noted that it was too heavy as one solid piece.

Our Solution

As designers themselves, Strand Design understandably did not want to hand over the design work to a third party. With that in mind, Hoosier Pattern worked side-by-side with the owners to redesign the oven and make this project a reality. The final design was broken up into parts so the oven was easier to handle—the 3D printed sand molds were printed within a really tight schedule and came out perfectly and ready to be cast.

Results & Conclusion

Ultimately, Strand Design opted to not only have Hoosier Pattern print the prototypes for the Fourneau Oven, but they also decided to have Hoosier Pattern complete the tooling as well for production. Strand Design's Fourneau Oven is just one of the many projects that prove Hoosier Pattern is the one-stop shop for prototyping projects that will ultimately need tooling in a short amount of time.

Our Competitive Advantage

Hoosier Pattern works very closely with each customer, enabling our designers to make changes on the fly and keep all projects moving forward to meet customers’ needs and deadlines. Hoosier Pattern's 3D sand printer operation is effective and more practical for quick turnaround times.

"Working with Hoosier was such a pleasure and they were so accommodating that we already knew before the prototypes were done that we would want to work with them to create the production tooling for the project" - Ted Burdett, Co-Owner, Strand Design

If you’d like to see the Fourneau Oven and learn more about how it works, click here