It’s a new year. At Hoosier Pattern, big things are already happening, and yes, we mean BIG. On Wednesday, January 6th, we were prepared for the arrival of a new Doosan NHP 8000, and even though it is the largest machine in the NHP line, many of our employees were still shocked by the size of this large delivery.
Above: The tool changer for the Doosan NHP 8000 arrives at Hoosier Pattern
Later in the morning, the rest of the machine arrived in one of the largest crates we have ever unloaded on our loading dock. This crate took extra-large forklifts, and a team of trained individuals that knew how to properly move these types of large machines began offloading our newest addition.
Left: a forklift finishes unloading the second crate containing the tool changer for the Doosan NHP 8000. Right: the machine arrives in a very large crate. This delivery was so large that it could only be on the road during daylight hours to keep other drivers safe.
The Doosan NHP 8000 has X travel 55”, Y travel 47”, and Z travel 53”. This machine is now our largest horizontal machining center in the shop. Hoosier Pattern made this purchase to upgrade an older horizontal machine that served us well over the years. The new Doosan will give us more options to machine foundry plates and 3D machining of foundry tooling.
Left: taking the walls from the crate surrounded by the Doosan machine requires multiple people and a lift to unscrew the bolts at the top of the crate. Right: the old machine being moved out of the shop to make room for the new addition
The Doosan NHP 8000 will be kept in a temporary location while its new concrete foundation is poured and cured. We are also adding a Renshaw inspection package that will allow us to inspect parts before removal to mitigate extra-unneeded setups, helping to improve our bottom line.
Above: the new Doosan NHP 8000 unwrapped and ready to be moved into Hoosier Pattern
Hoosier Pattern prides itself on continually being on the cutting edge of technology, and the addition of the Doosan NHP 8000 is no exception. We are very excited about this new addition to our shop floor. We project this machine will be ready to take jobs in February of 2021.
This article was provided by Waupaca Foundry and written by Allysan Melby. Read the original article here.
During the summer of 2018, a large storm whipped through the Waupaca, Wisconsin community, causing a couple of trees to fall, including some near the Hutchinson House and onto a historical bell residing there.
The Hutchinson House was built in 1854 and is a preserved home that resides in the Waupaca community, holding many treasures and artifacts from the Victorian era with many objects coming from Waupaca’s earliest settlers. One such artifact was an old school bell from Sunny View School, a one-room schoolhouse built in 1910 that operated as a place of learning until 1958. While the bell, dated to be from the late 1800’s remained intact, the storm had broken the over 100-year-old frame that held it upright.
The Waupaca Historical Society, not knowing what to do with the framework’s needed repairs, placed it into storage.
A few years later, Tracy Behrendt, the Waupaca Historical Society’s director, called upon one of the Society’s life members and special projects organizer, Lane Streck, to aid in fixing the bell’s framework.
Lane Streck, a hobbyist welder, began a plan of welding the pieces together. However, understanding the scope of the project and wanting future generations that visited the Hutchinson House to be able to ring the bell, he recommended that the Historical Society utilize Waupaca Foundry’s capabilities to create a long-lasting piece.
The Waupaca Historical Society then reached out to Waupaca Foundry to reconstruct the broken iron castings. The Plant 2/3 location’s layout department utilized its 3D scanning technology to scan the broken castings and reassemble the parts in a virtual 3D setting. Next, the new casting was reverse-engineered from the 3D scans to physical casting models. Tooling engineers utilized the scans to create 3D models and then gating systems to pour and then feed the castings.
Waupaca Historical Society volunteers (left to right) Jeff Weasner, Lane Streck, and Mike Kirk assemble and install the liberty bell using the new casting frame.
Waupaca Foundry then partnered with Hoosier Pattern to create a 3D sand printing of the mold for Waupaca
Foundry to utilize in its melt department. Once the mold was sent to Waupaca Foundry, the melt team utilized a small hand ladle to fill the molds with molten gray iron, allowing to cool for 30 minutes. The millroom then broke off the gating system surrounding the casting and shot-blasted the parts to get them clean. By utilizing gray iron for the bell’s framework, it increased the durability, strength and the component’s longevity.
Waupaca Foundry employees (left to right) Jacob Fell, Jon Huebner, and Nick Meyer hand-pour molten metal into the mold. The pattern was donated by Hoosier Pattern.
The new bell frame was then sent to Lane Streck where he painted the component black and reassembled it. This fall, the bell was placed again in the Hutchinson House’s backyard.
Since seeing the bell’s new frame Behrendt says, “It's just beautiful, and it looks perfect,” adding, “[Waupaca Foundry] used the same text on one of the sides that was on the old pieces, and then put the Foundry’s name on the back, which is wonderful that we'll be able to have a little bit of both histories — about the current history of that frame being built and mold being built, and then what it was before.”
When looking back on the project, it could have been easy enough to keep the bell in storage. However, the preservation of its history is an important part of what makes up the Waupaca community.
“History is so important, not only for us to just have an appreciation for those who came before us and to understand where the community came from but also so that we can learn and apply that to our future.” Behrendt says, “We have such a fascinating history. It’s so important to keep that going, and that's what [the Historical Society is] here for, and we feel like that we've been successful at it especially in the last five years or so, really trying to get the community involved in our history. This is just one of those ways, by having a project that another business or organization can help us preserve that history. Now, the foundry is part of [the bell’s] history. While they weren't connected with it in the past, they are now.”
2020 has definitely had its ups and downs. Although there is one silver lining worth celebrating, Hoosier Pattern is turning 23 years old! Despite these obstacles we faced, Hoosier Pattern remained a crucial part of the supply chain and adjusted to new policies and procedures during a global pandemic. We’ve expanded the shop and added new technology. We had to lean on each other and give each of us encouragement during hard times.
Being an essential business during a global pandemic has been nothing short of a challenge. After February, the COVID outbreak halted every in-person trade show. All of our company outings were canceled, and life inside the shop had to be immediately adjusted.
Face-to-face meetings, tours, and customer visits were wiped off the calendar. Overnight we began heavily utilizing the use of web conferences. We implemented temperature stations as well as extra sanitizing and cleaning procedures.
Today, we’re cautiously starting to open our doors to a few visitors and have resumed some face-to-face meetings. However, we’re still continuing to take every necessary precaution to ensure that everyone remains safe. In the future, we’re looking forward to further opening our doors for students and customers to tour our facility while staying connected with our patrons through our tradeshow events.
Looking back at 2020, the inside of the shop has continued to evolve. In January, we finalized the installation of our fourth 3D sand printer inside the shop, and we’re grateful for the extra capacity it has given us to take on more jobs. We added a new Doosan DNM 6700 to our CNC shop floor, and we developed a 360 virtual tour on our website.
Over the years, Hoosier Pattern’s success or secret sauce relies on our expertly-trained team that consistently serves our customer’s needs despite the difficult times they face. Our employees overcame adversity this year. They dealt with new protocols, changes in shifts and hours, limited contact with each other, canceled employee outings, and grieved the unexpected loss of a co-worker together.
Our employees dealt with all of those curveballs, but we never let our guard down. When it came to the quality of work or relationships with our customers, every team member rose to the occasion
In retrospect, 2020 has been filled with highs and lows. It was a year full of learning and challenging ourselves to think outside the box like never before. We are thankful to celebrate another anniversary and look forward to what the future has in store for us.
There are good days at work and there are bad days at work.
On occasion, there are days that just don't make sense.
The Hoosier Pattern family experienced one of those days that don't make sense when we unexpectedly lost one of our own last week. Cindy Wyss worked part-time and had just celebrated her two year anniversary at Hoosier Pattern. She was one half of our shop maintenance team and was part of the reason visitors always said "it's so clean in here!" when they toured our facility. Navigating being an essential part of the supply chain during the COVID-19 pandemic has been difficult to say the least. We doubled, if not tripled, our sanitizing and cleaning procedures. Cindy had no problem coming in for some extra hours every week to help with the increase in cleaning the facility. She never once complained about wiping down the same surface multiple times a day to ensure that we stayed as germ-free as possible.
Cindy's memory will always be honored by the Hoosier Pattern family as well as within our facility. Cindy worked part-time at another local business, Ritter's Flower Shop, for over 40 years. She's made hundreds of crafts and floral arrangements throughout the years for this community. One of Cindy's final crafts at the flower shop was a wreath that just so happened to have flowers with Hoosier Pattern's signature colors - blue and green. We knew right away that this special wreath belonged on our wall in memory of Cindy and as a way for employees to always remember her and her giving spirit. Hoosier Pattern will also be donating every year to a charity in memory of Cindy. This year we will be donating to Woodcrest Retirement Community as a way to honor Cindy's love for helping the elderly. Cindy also worked a third part-time job with home health care. She truly was one of the hardest working people in our building and she will be greatly missed.
Cindy was not only a hard worker, but she was also a friend to many people here. She was a loyal wife, mother, daughter, sister, and aunt. Cindy worked three part-time jobs to support her family and because of that, she did not have life insurance. Hoosier Pattern believes in leaning on each other in times of grief and sorrow as well as being a helping hand whenever and wherever you can.
We know that you would not be a fan of us talking about how great you are and would insist that we didn't gather as a group for lunch today to remember you. Some of us even think that the flood that happened in our break room this morning was a sign from you telling us that we aren't allowed to have the group lunch... or that our floors aren't clean enough. Either way, the thoughts of you gave us a small laugh and made us feel like you are still with us. We are positive that you would want us to push forward and keep living a life with a kind heart that serves others - and so that's what we will do. You will be greatly missed but we know heaven gained one of the good ones.
Your Hoosier Pattern Family
Click here to donate to the GoFundMe account to help Cindy's family with her funeral expenses.
At Hoosier Pattern, we take pride in our trade show booths. Whether it’s the 10x20 booth, the 10x10 booth, or the massive 20x20 booth, we have always spent many hours figuring out which specific items will go into our booths. Typically, we set up booths anywhere from four to five times a year all over the country. After setting up at each show, we wonder how we can make our booths even better and more appealing for our customers.
This pandemic has disrupted our 2020 trade show plans by canceling all our shows after the COVID outbreak hit the U.S. But these unforeseen events haven’t thrown a wrench in our trade show booth plans. With our 360 Virtual Tour’s success found on our website: HoosierPattern.com/tour, we wanted to find a way to bring the tour with us to shows.
This got us thinking, “what if we purchase a kiosk that allows customers to explore Hoosier Pattern’s shop from their fingertips using our virtual tour?”
To make this project a reality, Hoosier Pattern reached out to “GoToKiosk,” located in Monroe, Indiana. After visiting their offices and looking through various kiosks, we ultimately decided to design our own kiosk with the GoToKiosk team’s help. After a couple of months of production, the Hoosier Pattern 360 Virtual Tour kiosk was delivered to our front door!
Our new kiosk will be an exciting feature to our trade booths. Users will be able to see the wide variety of areas, including our collection of CNC machines, all four of our 3D sand printers, and the sand printing cleaning area.
We look forward to the 2021 trade show season, where we will be bringing this exciting piece of technology to every show with us!
October 2, 2020 marks this year’s Manufacturing Day, a day where manufacturing companies around the United States and the world celebrate their industry. Manufacturing Day is a time to educate those who are not in the industry by debunking some of the most common manufacturing myths. This day is traditionally spent with companies opening their doors to the public and giving them an inside look at their facilities. This year, companies are celebrating the day in their own virtual way.
We wish we could invite the community, local students, and families to celebrate with us and tour our facility – but this year we are doing things differently! We are inviting everyone to tour our facility by using our 360 Virtual Tour. We invite everyone to tour our facility, using our 360 Virtual Tour feature. You will get to view all of our departments including benching, sand printing, tool CAD/CAM, and more!
Opportunities at Hoosier Pattern
For some, Manufacturing Day is a great opportunity to learn about the industry and see if it would be a good fit for their future career path. Although we can’t invite you into our facilities today, we encourage you to learn more about us and the opportunities we offer on our website. If you'd like to learn more about our apprenticeship program, check out some testimonials from our current and past participants.
Aside from the apprenticeship program, we have many other ways to explore the manufacturing industry. We hire part-time help throughout the summer as well as job-shadowing with different departments. Joining the team as part-time help or to job-shadow are both great ways to get to know the industry better. If you are interested in any of these opportunities, feel free to contact our office today!
Although this day looks a little different from Manufacturing Days in the past we still see the importance of celebrating the industry and educating the community. Happy Manufacturing Day!
Hoosier Pattern has a new Journeyman Patternmaker! Brandon Fourman completed his 10,000 working hours as well as his classwork needed over the past 5 years to become a certified Journeyman Patternmaker. Brandon started working at Hoosier Pattern in September of 2013 and just celebrated his 7 year anniversary last week. He entered the apprentice program in August of 2015 and completed everything earlier this year and we were able to officially present him with his certification from the Indiana Department of Labor on September 23rd. All Hoosier Pattern employees were in attendance to see Brandon recieve his certificate. Congratulations Brandon!
Along with Brandon receiving his Journeyman Patternmaker certificate, we also celebrated some milestone anniversaries. Alyssa Corral and Spencer Wilson have been at Hoosier Pattern for 5 years as of 2020 and Tony Uhrick celebrated 10 years in 2020.
After employees were recognized, Tim Curry was introduced to the company. Tim was brought onto the team in early August as an outside salesman in an effort to broaden the Hoosier Pattern brand. time has over 35 years in the industry and is currently located in Houston, Texas but was in town for the week to tour our facility and meet his new coworkers. You can read more about Tim here.
It's been a weird year so far, to say the least, but at Hoosier Pattern we have always been committed to being a strong team and working together in order to do right by the customer and deliver the best product possible. We will always be a strong team, and we plan to stay that way even if 2020 has some more curveballs up it's sleeve.
Next week we were planning to be setting up the trade show booth at the Turbomachinery and Pump Symposia like we do every September, but 2020 had other plans. Most of the trade shows Hoosier Pattern planned on attending this year have been wiped from our schedule, but there have been some alternative solutions to exhibiting in person. Next Tuesday, September 15th, Hoosier Pattern will be participating in a virtual trade show hosted by Modern Pumping Today.
Although this is not a traditional trade show, it is a safe alternative to attending a traditional trade show in the midst of a pandemic and there are many pros to having a virtual event. First and foremost, this virtual show is FREE to attend! For exhibitors and attendees, there is no traveling or time spent out of the office. As much as we love getting out of the office and talking face to face with current and potential customers, missing a week of work doesn’t stop the work from piling up on our desks at home. Even though there are no face to face interactions, the Modern Pumping Today platform is set up so that visitors can talk live with company employees, download info, or watch videos. When visitors click on our booth, there will be a section to ask questions and speak to a real employee in real-time. This virtual event will also include educational videos, pre-recorded webinars, and plenty of product information video content the user can choose from to watch.
Hoosier Pattern has always embraced technology and has never been afraid to try new ways of doing things. We look forward to being a part of this virtual event and making it successful. Register to attend this virtual event for FREE here: https://highlandspublications.com/mpt-expo-for-more-information/
Learn more about Modern Pumping Today here: https://modernpumpingtoday.com/
As far as 2020 trade shows, there is one more on the calendar that is still planning on happening. The Performance Racing Show in Indianapolis, Indiana held at the Indiana Convention Center from December 10-12th. Read more about that show here: https://www.performanceracing.com/tradeshow
When Cory Taulbert of Taulbert Chassis Components reached out to Hoosier Pattern to work be apart of this project, we didn’t realize how cool the results would be! Hoosier Pattern’s 3D sand printers created molds for an intake manifold that ended up being a part of a Cadillac V8 rebuild.
Bill Ganahl (South City Rod and Custom) is currently building a hot rod for client Mark Warrick. The 1936 Ford 3 window coupe hosts an immense amount of subtle custom touches, something South City Rod and Custom is known for. Under the hood sits a 1955 Cadillac V8.
Engine conversions were very common in the early days of hot rodding, as it offered the owner an easy way to get more power as Detroit rolled out better engines. In parallel, the aftermarket quickly supported the new engines with custom camshafts, multiple carburetor intakes, and even supercharger systems.
A company called Supecharger Company of Turin (SCoT) sold superchargers of various displacements for popular engines, but more importantly, produced the intake manifolds that allowed everything to be bolted together. Fast forward to today, some of these parts are still around but the original limited-production has made those parts extremely rare today.
Back to Mark’s 1936 Ford – he wanted to put a SCoT supercharger on the Cadillac V8. Bill had the tall task of locating an original SCoT intake to put the package together, but there were none to be found (that were for sale anyway). Bill turned to a friend, Cory Taulbert, to see what they could come up with.
Cory suggested that they make a new intake manifold. This would allow them to custom tailor it to Mark’s car, as well as give Mark the exclusivity to unique “one-off” part. Cory offered up the CAD services and got to work designing a new intake manifold, with inspiration from the original SCoT intake manifold.
When it came time to actually make it, Cory reached out to Hoosier Pattern. He had recently seen a friend working on a 1920’s Packard Indy Car engine block, that was created from scratch. Hoosier Pattern 3D printed the molds, so it was clear that it was the place to go to.
At Hoosier, Todd Yoder worked with the 3D model to develop the 3D printed molds. The molds were then shipped to Crystyl Engineering in Piqua, OH, where an aluminum casting was poured and heated treated. To finished off the casting, Tooling Science Inc in Maple Grove, MN finish machined the interfacing surfaces and flanges.
It’s always very exciting to see a project that we were a part of come together in the end and even better when we get to share these projects with the rest of the industry. The possibilities with the 3D sand printers at Hoosier Pattern are truly endless. Need a quote for a project that requires 3D printed sand? Go here.
Every year Hoosier Pattern enjoys taking in internships, externships, or job shadowers, and this summer we had Clay Barlow in the shop with us! Clay has been with us all summer throughout different areas of the shop. Learn more about Clay's experience in his own words below.
Purdue University - West Lafayette, Junior in the fall of 2020 and I am majoring in Materials Science and Engineering
What made you seek out Hoosier Pattern as a place to work at for the summer?
It was an opportunity to work within my area of interest for the first time. Not only that, but it looked like and proved to be true that Hoosier Pattern is a place that does a lot of things and does them all well. Also, they are consistently innovating and are leading their industry. I was excited long before I arrived and I wasn't disappointed.
What types of things did you do at Hoosier Pattern?
I've been able to do a lot and got experience within every department over the course of my internship. My main role was to work on improving the 3D plastic printing capabilities, but I also worked with machining, sand printing, and on other projects.
What did you enjoy about working at Hoosier Pattern?
I enjoyed that there is never a dull day and that each day, each hour, you will be working on something different. Not only that, but it seems like Hoosier Pattern is focused on continuously improving all parts of the company and to be a part of that type of innovation is awesome. Last but not least, it's a very friendly, almost family-like, atmosphere. You have a lot of responsibility and freedom to get things done and if you happen to mess up, the people here are nothing but supportive and helpful to fix the problem.
What were some memorable projects you got to work on and participate in?
3D printer optimization: I got to dial in the printer and slice parameters to begin producing carbon fiber infused plastic parts. I also got to work on integrating soluble support into our parts to improve support removal and surface quality.
Centrifugal ISO-Finishing Inquiry: I produced a part in 4 materials to explore a new
Casting made from a sand printed mold: I got to design apart from a print and then had the mold sand printed and got to pour molten aluminum into it to create a casting. (pictured above)
What do you want to do as a career? DO you think that working at Hoosier Pattern during the summer will help you decide on what you want to do as a career?
I am hoping to land in the foundry or at least in the wider metals production industry. working at Hoosier Pattern has already helped me with career decisions by solidifying it in my mind and allowing me to gain an extracurricular real-life experience within the industry. I also got to see another side of the casting world.
Other than the job itself, what kind of things has Hoosier Pattern taught you?
While at Hoosier Pattern, I've learned a lot about being a better professional, engineer, and person. Outside of the job skills, I learned a lot about managing multiple projects at once and making sure goals get met in a timely manner. I learned better ways to communicate, especially across the company and outside of the company. just in talking with the others in my workspace, I got info on professional networking, on the foundry industry, and on things completely outside of work like general life skills and advice.
Outside of work, what do you enjoy doing? What organizations are you involved in at school? Do you play sports?
I enjoy cooking, spending time outside, tinkering, and making stuff and hanging out with friends and family. At school, I'm mainly involved as a leader in volunteering and professional organizations including Purdue's chapters of American Foundry Society and Material Advantage. as for sports, I'll play football or basketball with friends or run and lift also.
Clay's last day at Hoosier Pattern will be this Friday, August 14th. Good luck at Purdue this fall, Clay!