In the metal casting industry, two basic pieces are needed: a mold of some sort and a foundry to pour the mold. A traditional pattern shop supplies the pattern while a foundry packs sand around the pattern to make the mold. From there, The mold is poured resulting a casted part.
Hoosier Pattern fits the bill of the traditional pattern shop, but our expanded capabilities give us a competitive edge with the addition of our in-house 3D sand printer. By printing ready-to-pour-sand molds, we are able to bypass the tooling, possibly saving our customers time and money.
Since purchasing a 3D sand printer and having it in our facility since 2013, HPI has made strides within new and diverse industries. The possibilities with sand printing are almost endless and with the HPI team, we try to make every "out of the box" concept a reality.
We are always looking for new customers and ways to solve problems within the industry. When talking with new and potential customers we are often asked questions like the following:
"How do we know when we should use 3D printed sand for our projects instead of using traditional foundry tooling?"
"What are the advantages of sand printed parts?"
"How would using 3D sand printing benefit my project?"
Since 3D sand printing is still a fairly new process in the industry, it's important to give our clients a detailed overview of what to expect when starting a new project with this process. If we had to sum up the benefits of 3D sand printing in a few points, we'd be sure to hit on the following:
Perfect for Prototypes
Sand printed molds and cores are printed from a CAD file and are a one-time use. This process makes printed sand molds and cores ideal for prototyping parts. CAD files can be altered in a very timely manner, allowing for quick changes to the design if needed. Customers are able to avoid paying for tooling that is produced and priced to be used hundreds or thousands of times.
Multi-Piece Core Assembly With A Single Printed Core
Eliminate multi piece core assemblies by printing a single “merged” core to eliminate mud joints and improve accuracy of core.
Easy to Manufacture
In the world of pattern-making and design, it's not uncommon for engineering changes to pop up. In traditional pattern-making, these changes no matter how small, can pose a problem once the tooling has been produced. Since our 3D sand printed molds and cores are printed from a CAD file, the customer is able to create and design geometrically complex castings to be manufactured with ease. Designs don't have to be compromised in order to meet low-cost, high-functioning manufacturability.
The conventional method of building a pattern can take anywhere from weeks to months. HPI's standard lead time for 3D printed sand is 2 weeks, with the option of 1 week and 3 day expediting available. This turnaround time includes printing, cleaning and packaging the parts, followed up by sending the item to a foundry to be poured.
The printer at HPI has a job box the size of 70" x 39" x 27" and prints about 1.3" every hour. A full job box takes anywhere from 19-23 hours to print, making for an incredibly quick turnaround.
Hoosier Pattern is rooted in traditional pattern-making and will continue to produce high-quality traditional foundry tooling. However, the 3D sand printer opens opportunities to work with clients who need smaller quantities and quicker turnarounds. It is a tool in the HPI toolbox used to help customers with projects and set us apart from the competition. In fact, Hoosier Patternis the only place in the United States that owns and operates equipment in house and supplies high-volume production tooling.
Our in-house printers and dedicated team members work diligently and consistently to bring the best products to our customers. We will continue to raise the bar within the industry and always work to improve our company and our products, because our customers deserve the best.
Next week, AFS 121st Metalcasting Congress kicks off in Milwaukee, Wisconsin and Hoosier Pattern will be showcasing on the sold out exhibit hall floor. The AFS Metalcasting Congress is the industry's largest conference and trade show that brings together suppliers, foundries, and casting customers alike. The conference brings endless opportunities for networking, promoting, and educating people on a larger scale about Hoosier Pattern’s role in the industry.
Dave Rittmeyer, Steve Murray, Alyssa Corral and Brandon Fourman will be representing HPI at the show. They will be a part of panel discussions and be at booth #510 in the exhibit hall.
Having just celebrated his 18th work anniversary with Hoosier Pattern, Dave is a familiar face within the industry. As a journeyman pattern-maker with more than 2 decades in the trade, as well as being HPI's additive manufacturing supervisor, Dave has a well-rounded knowledge of the industry. At the conference, he will be part of a foundry technology panel on Tuesday morning in room 203AB at 9:15 AM. He will be discussing 3D printed sand and how to apply the technology to projects for customers. When Dave isn't at Hoosier, he enjoys riding his Harley, fishing, and spending time with his wife and 4 sons.
As a journeyman pattern-maker with a passion for the foundry and metal casting, Steve has been a huge asset to the team with his knowledge of the trade and additive manufacturing. Instead of having a desk in our facility, Steve is normally out traveling and educating potential customers, foundry men, engineers, and casting designers finding the best solution to their casting needs. Steve will be part of a panel on Tuesday afternoon at 1:30 PM in room 202AB discussing additive manufacturing. When Steve isn't traveling for work, he is spends time woodworking or hanging out with his wife and grandkids.
Entering into her third year at Hoosier Pattern, Alyssa Corral specializes in all marketing and social media efforts, along with producing and managing website content. Alyssa is always looking for new ways to tell Hoosier's story within various industries, especially by attending trade shows and participating in that way. When she isn't on the clock, you can find her at record stores looking for Beatles records, at a concert, or reading a book somewhere.
Brandon Fourman is an apprentice pattern-maker and has been with HPI since 2013. He started in the saw department and was accepted into the apprentice program in June of 2015. Brandon will be a new face in the trade show booth, but is very knowledgeable and will be a great asset to the show team for the Metalcasting Congress. In Brandon’s free time, he is usually hunting, fishing, or on a golf course.
HPI started in 1997 as a pattern shop and has seen continual growth within the pattern industry by expanding our capabilities to what they are today. We hope you’ll stop by our booth at the conference and check out photos and videos of our facility, as well as sample projects we have worked on. HPI's booth will have information and literature about all services that we offer including foundry tooling, 3D printed sand, and plastic/ABS printing. HPI is proud to be a part of a community and industry that is so vital to everyday life. We look forward to exhibiting and meeting with current and potential customers, as well as seeing which direction the industry is heading in.
Never used or even seen 3D printed sand? Hoosier's booth will be filled with 3D printed sand molds and cores, as well as castings that were cast from 3D printed sand. Everything from small castings to large castings, all made from 3D printed sand in a range of alloys. All of our 3D printed sand is printed in-house with one our ExOne S-Max™ printers in the shop. Have a project or idea that could possibly use 3D printed sand? Stop by the booth. We'd love to hear your idea and discuss your options. See you next week!
Next week, Dave and Alyssa will be at the 45th Turbomachinery and 32nd Pump Symposia in Houston. TPS is the premier training and networking opportunity for professionals in both pump, turbomachiniery and related industries. Last year, TPS attracted more than 5,500 people and 350 exhibiting companies from 48 countries. HPI fits into this show because here at HPI, we are able to manufacture parts for a wide variety of industrial pumps and commercial pumps, including: centrifugal pumps, water and sewage pumps, turbine pumps, transfer pumps, fluid flow pumps and more! Pump castings can be delivered with pinpoint accuracy in just days with our advanced technology and multi-industry expertise.
Why Use 3D Printed Sand to Make Pump Components?
In a maximum of 2 week's time from the receipt of your purchase order, you can have a sand mold of your pump component ready to ship to the foundry of your choice. Don't have a foundry in mind? No problem. We have a network of foundries we work alongside to produce high quality castings for our customers. The sand molds are ready to make a casting with no waiting for foundry tooling to be made, refurbished or changed to the latest engineering level. Castings get made faster and into your customer's hands quicker. This process is ideal for new prototypes, low volume pump requirements, and legacy pumps or their components.
The cost for 3D printed sand components, sand molds or sand cores is $0.13 per cubic inch. This is the cubic inch of the CAD build box of the sand component. No extra charge for complex designs or geometries. The only extra charges are if you want it NOW, like the next day NOW. Yes, we can do that.
Complex geometries of your parts do not equate to higher costs to make your castings. You do not need to sacrifice your design for manufacturability. Complex core designs are 3D printed as one piece, thus reducing or eliminating assembly errors and foundry casting defects. No internal fins or mismatches. 3D printed foundry molds do not need traditional parting lines and flask sizes. This gives the foundry the freedom to gate, place risers, and feed the casting in the best way possible to produce the optimal casting. The freedom of pump design combined with the freedom of the foundry to manufacturing a pump component casting is a huge advancement for the pump industry.
Complex pump component castings produced quickly and at a known cost is why manufactures are turning to 3D printing as a solution to pump casting problems.
See you next week, Houston! If you are not going to be at TPS 2016, but are still interested in 3D printed sand for your pump project, please contact us.
In June, Hoosier Pattern was awarded a Global Supply Chain SOLVE Solution Award by Emerson Process Management. Emerson gives this award to outstanding project owners that impact the way their supply chain works. The objective of The Global Supply Chain's Solution Award is to encourage and recognize people's efforts on providing supply chain related solutions to the business. In line with the SOLVE vision (defined below) there must also be value added to the business via enterprise engagement, financial improvement, delivery improvement and asset management improvement. The Solution Award is going to be given once in a calendar year and/or completion of a Solution project. The nominees for the award are individuals and/or teams inside and outside of the Global Supply Chain's organization and recipients are chosen by Global Supply Chain leadership, in alignment with Enterprise Leadership. Hoosier Pattern is the only external supplier to receive a Solution award.
Global Supply Chain's vision of SOLVE includes:
S - Solution provider on: delivery challenges, dwell time and asset management targets
O - On-time delivery improvement with all suppliers achieving 95% OTD to request date
L - Lead time reduction: work with suppliers to shorten lead-times demanded by KOB's
V - Value add to our financial position: deliver supply chain related financial targets on NMI, DPO, ES
E - Enterprise engagement via perfect execution: driving regional actions in line with global Enterprise objectives
HPI is honored and thrilled to be the recipient of the SOLVE award. Our employees take pride in their work and the quality of everything that leaves our facility reflects that. We will continue to strive to be an industry leader in 3D printed sand, constantly working to be better and finding ways to do things differently. The HPI team is mindful of the need to compete for excellence and will always work together as one to keep that goal in mind. We look forward to our future with Emerson and continuing to make that partnership a stronger one.
Hoosier Pattern put on it's first webinar Wednesday May 25th. Titled, An Introduction to 3D Sand Printing for the Metalcasting Industry, the webinar was presented by Steve Murray and Dave Rittmeyer of Hoosier Pattern. Both Steve and Dave have been in the trade for over a combined 50 years. Both Journeymen are well educated in additive manufacturing and have spoke at multiple events about this topic.
Steve Murray and Dave Rittmeyer of HPI
Incase you missed it, we had the webinar recorded and it is available to watch here and on our YouTube channel.
If you have any additional questions regarding the webinar, want to receive any of the literature mentioned, or would like to talk to the presenters themselves, feel free to contact Steve or Dave.
Steve Murrray: email@example.com
Dave Rittmeyer: firstname.lastname@example.org
Customer: Strand Design; Chicago, Illinois
Part: Fourneau Bread Oven
Batch Size: Prototype to Tooling
Material Cast: Gray Iron
What it is:
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 golden, crispy crust.
Strand Design came to HPI many different times with multiple design molds for the oven that weren't possible due to the way it was designed. The designers asked HPI to reengineer the molds to add proper gating and risers to have it done within a short time span. Once the design was tested, it was noted that it was too heavy as one solid piece.
As designers, Strand Design did not want to hand over the design work to a third party. So, Hoosier Pattern worked side by side with the owners to redesign the oven to make this project a reality. The final design was broken up into parts so the container was easier to handle. The 3D printed sand molds were printed within a really tight schedule and came out perfectly.
Ultimately, Strand Design opted to not only have Hoosier Pattern print the prototypes for the Fourneau Oven, but they decided to have Hoosier Pattern complete the tooling for it as well. Strand Design's Fourneau Oven is just one of the many projects that proves Hoosier Pattern is the one stop shop for prototyping projects that will ultimately need tooling in a short amount of time.
HPI Competitive Advantage:
Hoosier Pattern works very closely with all customers enabling our designers to make changes on the fly to keep all projects moving forward to meet customer's needs and deadlines. Hoosier Pattern's 3D sand printer operation is effective and more practical for quick turnaround times.
It was a very exciting mail day when we recieved our own Fourneau Ovens. Congratulations, Strand Design on this awesome product you have made. Hoosier Pattern is excited and proud to be apart of it. Happy Baking!
Specifically in the additive manufacturing side of our business. By now our 3-D sand printer is not a secret, and although Hoosier Pattern was the first pattern shop in the United States to use this technology for commercial use, more sand printers are being bought and the competition is slowly rising. HPI has always strived to be an industry leader and a customer's first choice when needing 3D printed sand parts. HPI continues to grow and adapt to changes and demands in the industry. As of lately, HPI has hired more employees in the sand room to help extract and clean sand printed parts to stay on top of the demand and stay true to our promise of "On Time Delivery". Along with more employees in the sand room, HPI has also hired another employee to help build job boxes for the sand printer, as well as help get quotes back to customers.
Expanding our team is great news here at Hoosier Pattern, but we have also made some exciting changes for exisiting and potential customers. We are pleased to announce that we have reduced the cost of sand printing! Contact us today to see what our new prices can do for your next project.
"This technology enables us to service commercial and defense OEMs and their affiliated foundries even if they don't have a pattern on hand." - Keith Gerber, Hoosier Pattern
That quote from Keith was from an article about additive manufacturing for defense contractors in National Defense Magazine. The article talks about how the military utilizes additive manufacturing to solve the problems of cost and long lead times of tooling fabrication.
RAPID was 3 days of educating, exhibiting and exciting discoveries of what is happening in the world of 3D printing. The Long Beach Convention Center was buzzing for 3 days with students, industry experts and exhibitors networking with each other, and Hoosier Pattern's Dave Rittmeyer, Steve Murray and Alyssa Corral were all there to take it in.
Monday night included a welcome reception sponsered by SME and Materialise, which included endless networking opportunities as well as appearances by Elvis and The Blues Brothers!
Tuesday, Wednesday and Thursday were days full of exhibiting. With over 200 exhibitors present, there were endless things to see and discover in the 3D printing world including 3D printed dresses and shoes, as well as a fully printed motorcycle and a car with over 70 3D printed parts.
The most visited as well as the biggest thing present on the exhibit floor at RAPID this year was Bodock, the Giant 3D Printed Monster. Stratasys partnered with the Stan Winston School of Character Arts, Legacy Effects, WIRED, and Condé Nast Entertainment to produce a 14-foot tall creature to introduce at Comic-Con International in San Diego in July of 2014. Bodock was made using 6 different 3D printer, and it takes 4 people to operate him.
RAPID had many cool features to it, but perhaps one of the coolest was the RAPID App for people attending the show. The app was free to download on any smart phone or tablet and included all of the exhibitors and their location, conference schedules, attendee lists, maps, as well as a live news feed giving attendees and exhibitors yet another way to communicate and interact with eachother. It took being a part of a trade show to another level of communication and networking.
RAPID 2015, for Hoosier Pattern, was a very busy week filled with connecting, learning and educating exhibit goers about how HPI fits into this evergrowing world of 3D printing. Our S-Max™ 3D sand printer has endless possibilites and is ready to help you with your next project.
Contact us and send us your CAD files for a quote today!
The year is flying by and we are quickly approaching RAPID 2015. RAPID is being held in Long Beach, California at the Long Beach Convention Center from May 19th to the 21st. It is known worldwide as the preeminent event for 3D printing, scanning and additive manufacturing. With less than a week to go, we are packing our sunscreen and getting very excited to be a part of the largest additive manufacturing conference in North America.
Hoosier Pattern will be at booth #1134 with an exciting opportunity for booth goers. Hoosier Pattern is offering a freesample mold that has been printed in our S-Max™ 3D Sand Printer to anyone who stops at our booth. The sample mold comes pour ready with the gating and riser already printed in it.
Above: A pouring man sample mold given out by Hoosier Pattern.
We have one of the largest 3D Sand Printers in existence here at Hoosier Pattern.
Please contact Hoosier Pattern to see if we can help with your next project. We can rapidly prototype parts with complex internal geometries and reduce lead time from months to days.
Are you going to be in the Long Beach area next week?
Do you want to attend RAPID 2015 as our guest? Let us know!
We have extra tickets that will get you into the RAPID Exposition free of admission (a $75 value)! Please contact our social media coordinator, Alyssa, to get your ticket or promo code to register for the expo online. Contact Alyssa by calling 260.724.9430 or by email at email@example.com
Hoosier Pattern will be in Long Beach, California at RAPID 2015
RAPID is being held in Long Beach, California at the Long Beach Convention Center from May 19th to the 21st. RAPID is known worldwide as the preeminent event for 3D printing, scanning and addititve manufacturing. RAPID is filled with cutting-edge 3D innovation as well as many experts of additive expertise across all industries. RAPID is the largest additive manufacturing conference in North America. 3D technology is constantly growing and expanding, RAPID is a place to explore all the ways 3D technology can help advance your business. With more than 200 exhibitors, attendees will have the opportunity to engage with industry leaders and presentations presented by them.
Hoosier Pattern's Dave Rittmeyer and Steve Murray will both be leading workshops at RAPID this year.
Designing Printed Molds and Cores That Can Be Cleaned and Handled
Tuesday May 19th 2:00pm-2:25pm Dave W. Rittmeyer, Customer Care & A.M. Manager, Hoosier Pattern, Inc.
Just about any CAD person can design a mold or core, but their design may or may not be able to have all of the unbound sand completely removed. They also have to be designed so that they can be safely handled. Some designs can make it impossible to remove all unbound sand. But there are some practices that can be followed to help increase the chances for successful removal of the unbound sand. There are any ways to handle printed sand safely. I will review some of the options that we ahve tested and used successfully.
How to use 3-D Printed Sand in Short Run Production and Prototype Castings
Tuesday May 19th 3:00pm-3:25pm Steve R. Murray, Sales Rep and Additive Manufacturing Consultant, Hoosier Pattern Inc.
What foundry components can be 3-D printed in sand -- Molds Cores. Why use 3-D printed sand to make foundry molds and/or cores. No need for traditional foundry tooling. It's a timing issue and eliminated cost of the tooling. No draft required thus reducing CAD design time. More iterations done faster. No penalty for complex designs. Core assembly is eliminated. How to integrate riser sleeves both insulating and exothermic in to your 3-D printed sand mold. Placing filters in your printed sand mold. Printed sand cores. Solid, shell or a hybrid. What each can bring to your design and your casting. Using ceramic cores in a sand mold. Designing your printed sand mold for safe handling.
We just finished putting all of our booth and supplies in the crate, the next time we see it, we will be in California! See you at RAPID 2015!