General News

HPI To Host Manufacturing Day Event for Students and Educators

Manufacturing Day is nationally recognized every year on the first Friday in October and is used to showcase the reality of modern manufacturing by encouraging thousands of companies and educational institutions around the nation to open their doors to students, parents, teachers, and community leaders.

Although Manufacturing Day falls on October 4th this year, Hoosier Pattern is opening its doors to students, educators, school officials, and local government officials to tour our facility and see what goes on day to day behind the doors at HPI. Guest will be able to check out each area of the shop as well as be able to talk with employees and ask any questions they may have.

Multiple CNC centers on the shop floor will be running and the 3D sand printers will be printing job boxes in real-time. There will also be a finished job box with 3D sand printed keychain molds inside. Visitors will be able to extract their own molds, clean them at a cleaning station and then take them to be poured here in the shop and be able to take a custom keychain home with them.

When visiting local schools and talking to local students, we always ask students what they think of when they hear the word “manufacturing”. We get answers like “dirty”, “low paying”, and “bad hours”. Hoosier Pattern strongly believes in encouraging the younger generation to explore careers in manufacturing and take every opportunity to show these students that those stereotypes are just simply not true.  We encourage all students and educators to join us on Wednesday, October 2nd at Hoosier Pattern as we help inspire the next generation of manufacturers.  

If you are an educator and want to get your class here for this event please contact Alyssa Corral at alyssa@hoosierpattern.com or directly at 260-706-4144

To learn more about Manufacturing Day and check out other Manufacturing Day Events check out their website: https://www.mfgday.com/

3D Printed Sand Molds and Cores for Pump Components at TPS 2019

In two weeks, HPI's Dave Rittmeyer and Alyssa Corral will be in Houston, Texas at the 48th Annual Turbomachinery and Pump Symposia. TPS is a worldwide event with exhibiting companies from all over the globe exchanging ideas to grow the industry further. TPS is known for its impact on the turbomachinery, pump, oil, gas and petrochemical power, aerospace, chemical and water industries. Typically there are over 4,500 attendees and 350 exhibiting companies from 45 different countries. The show floor spans over 200,000 square feet and is filled with industry experts demonstrating full-size equipment and products. 

 

HPI will be at booth #1226 with 3D printed sand molds and cores as well as some castings that were cast from like molds and cores. The HPI booth is always filled with plenty of videos and visual media to help answer any questions as well as information for customers and potential customers to take with them. If foundries have never poured the 3D printed sand, we encourage them to stop by the booth to get their badge scanned to have some free samples sent to them. 

 

Why Use 3D Printed Sand to Make Pump Components?

Timing:
In a maximum of 2 weeks 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.

Cost:
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. 

Design:
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 massive advancement for the pump industry. 

Complex pump component castings produced quickly and at a known cost is why manufacturers are turning to 3D printing as a solution to pump casting problems.

 

See you in two weeks, Houston! If you are not going to be at TPS this year but are still interested in 3D printed sand for your projects, please contact us. 

Meet Ian and Colin! | High Schoolers in Manufacturing


It's already been a busy summer here at HPI and it's only the middle of June! Every year, HPI looks into bringing high school aged kids to job shadow or actually be hired in to help out where needed in the shop to get a feel for what the manufacturing industry is like. Along with getting hands on experience, these summer positions also give these students a taste of what having a job in the "real" world is like by teaching them soft skills such as showing up to work on time every day and being a part of a team. This year's summer employees come from Adams Central High School and Norwell High School. Everyone meet Colin Rittmeyer and Ian Smith!

 

 

Colin Rittmeyer
Norwell/Senior

What made you seek out HPI as a place to work at for the summer?

My father works here and I’ve worked here before.

What types of things do you do at HPI?
I work in the sand room – extracting job boxes, cleaning cores and packing them to be shipped to foundries.

What do you enjoy about working at HPI?
I really enjoy the relaxed work environment.

What do you want to do as a career? Do you think that working at HPI during the summer will help you decide on what you want to do as a career?
I’ve been planning on going into the Marine Corps which I had decided to do 4 years ago.

Other than the job itself, what kind of things has HPI taught you?
How important attention to detail is.

Outside of work, what do you enjoy doing? What organizations are you involved in at school? Do you play sports? 
Cooking, playing baseball and PT with the Marine Corps recruitment program.

 

 

Ian Smith
Adams Central/Junior

What made you seek out HPI as a place to work at for the summer?
I have seen all the things they do for their employees and I hope to make a career out of this. 

What types of things do you do at HPI?
I do a lot of mold cleaning and then packing them to be shipped to foundries.

What do you enjoy about working at HPI?
Getting a half day on Friday. 

What do you want to do as a career? Do you think that working at HPI during the summer will help you decide on what you want to do as a career?
I would like a career in machining or mold making and after working here I feel like my choice to do that has been justified.

Other than the job itself, what kind of things has HPI taught you?
Respect, honesty and work ethic

Outside of work, what do you enjoy doing? What organizations are you involved in at school? Do you play sports? 
I wrestle and play football. Last year I was part of the skills USA contest for machining and I placed fourth in the state for Milling Specialist. 

 

While we understand the appeal of summer vacation for high school aged kids, we think it is really impressive that these students have seeked out local opportunities to make some extra cash. It is admirable,  shows a good work ethic and we look forward to showing these students how we do it here at HPI. Welcome to the HPI family for the summer, Colin and Ian! 

 

HPI hires new employee via Signing Day

The Adams Wells Manufacturing Alliance (AWMA) held a signing day event for local students that have been enrolled in a work-based learning program in high school and have decided to work full time for these businesses after graduating. Connor Ray came into Hoosier Pattern last summer and inquired about a job. HPI was impressed with his motivation and initiative to plan for his future after high school and hired him. He went to school half day then worked half day and lastnight at the signing day event, HPI signed him as a full time employee. Connor was one of 10 local graduates that signed to work full time with area businesses. Every signee received a $150 signing bonus from the AWMA. Read about the full list of signees here.

Connor will graduate from Heritage High School on Sunday and we look forward to a future with him here at HPI. Congratulations to Connor as well as the rest of the Class of 2019!

  

Read more about the AWMA and what they do here.

HPI at Cast Expo 2019

 

We are a little over 2 weeks out from Cast Expo 2019 being held in Atlanta, Georgia and Hoosier Pattern is excited to be on the exhibitor floor this year at booth 729.  Since the last Cast Expo in 2016, Hoosier has added multiple machining centers, a new 5-axis machining center, 2 Johnford Bridge Mills, a new laser scanner, a robotic milling cell and a third 3D sand printer in house.

For the first time ever, Hoosier Pattern has a 20x20 booth and will have a full size job box like one of the ones from our sand printers in the booth showcasing the size of sand we can print. We will also have AFS keychain molds that can be taken straight from our booth over to the foundry in a box at the AFS Hub to have poured right there at the show.

As much as we love emails and phone calls from current and potential customers, nothing beats face to face time with each other and networking outside of the office. We look forward to having the industry at our fingertips and being able to connect with colleagues at the show. Another new thing we are featuring in our booth this year is the ability to look at your CAD files on site in our booth. If you would like, feel free to bring your CAD files (.stp or .x_t files preferred) to our booth and we will review them on site. See you there!


What is Cast Expo?
Cast Expo is the flagship event of the American Foundry Society.  Every three years, over 6,000 attendees will come together under the same roof to explore, network and supply opportunities in metal casting as well as related industries.

Registration for Cast Expo is available for AFS Members and non-members. Visit the Cast Expo website to register.

Important info to remember:
• Event: AFS Cast Expo 20194
•Location: Georgia World Congress Center, Atlanta, GA
•Dates: April 27-30, 2019
•Hoosier Pattern Booth: 729

35-Member Delegation from Adams and Wells Counties Tours Vincennes Campus

The Tour was part of an ongoing effort to establish a Workforce Center in Decatur with Vincennes as an anchor tenant

Decatur, IN – In the early hours on Monday February 11th, a charter bus filled with prominent community leaders rolled out of town on its 240 mile trek to Vincennes University in Southern Indiana.  Amongst those traveling with the group were city and county officials, influential business people, community based non-profit groups, and officials from multiple school districts.  The trip was organized by a few business leaders and community representatives that have been discussing turning a local building into a Career Training center.

 “We have been in dialogue with Vincennes University for the last few months about offering workforce development and educational services from within Adams County to serve as a regional resource,” explained James Teeple, Workforce Development Director for Adams County Economic Development.  “A consortium of regional leaders was invited to journey with us to Vincennes to confer with the university’s president, Chuck Johnson and his administrative staff.”

“The university provided a very insightful tour of both the Vincennes Campus as well as their Gene Haas Technical Education Center in Lebanon,” Teeple continued. “They have reiterated their commitment to support the implementation of an educational service hub or career center in Decatur. The intent of the trip was to demonstrate potentiality of such services and resulting economic impact to the region. From that perspective it was a very worthwhile outing.”

Local businesses are very supportive of the endeavor as it is important for their current needs as well as the longevity of their companies.  Decatur business owner Keith Gerber shared his company’s struggle and why this is important to businesses.  “Workforce Development for Hoosier Pattern is cultivating from within our Adams/Wells High Schools. This bus tour gave us a vision of what is within our grasp to create a community career center. It would allow us to skill up our present workforce, as well as develop an awareness and the skills needed for high school students for well-paying “no debt” careers. We currently struggle to find qualified employees amongst current potential applicants. A career center along with better marketing ideas to attract these students to take a look at what we have to offer is crucial for longevity for my business.”

Overall the event was very successful.  As the bus pulled back into town late that evening, Adams Wells Manufacturing Alliance’s Director, Joe Elkins, summed it up best, “I was very impressed by the "Hands On" approach taken by Vincennes University.  The skills taught there can result in high-paying jobs that are sorely needed by Adams and Wells County manufacturers.”

 

write up provided by Trevor Hobbs

New Year; New Equipment

We are one month into 2019 and things have already been happening here at Hoosier Pattern. 2018 was a crazy year and we are looking forward to what 2019 has in store, not only for us as a company, but for the industry as a whole. Last year was a year of expansion for HPI. In July, we added a third sand printer as well as expanded the sand cleaning/packing  area giving us room to expand increased printed product from these sand printers.  

In the fall of 2018, HPI added 2 Johnford bridge mills to our list of machinery. Both bridge mills have the same travel size of 83”x 70” The size capacity of these bridge mills allow us to take on larger jobs that once had to be turned away.


Journeyman Patternmaker, Phillip Bauman and Apprentice Patternmaker Kyle Rittmeyer, collaborating on a project infront of a Johnford bridge mill

We also announced last year that we were installing a Kuka™ robotic milling cell. This robotic milling cell allows us to machine foundry sand molds or plastic patterns. As of now we are able to mill sizes up to 60x100”. Training on the robotic milling cell for our workforce will take place in early February to help educate our team to communicate with the robot. This new technology will give our customers more tools to assist them to bring their finished goods to market sooner.  Be on the lookout for updates regarding the robotic milling cell.
 
The new robotic milling cell in the shop 

Lastly, we added a new Creaform™ laser scanner to our list of technology. New training for this scanner has been underway to enhance our knowledge and better provide quality inspections of our machined products.


The new Creaform™ laser scanner in the quality room ready to be put to work on some practice scans

 

Customers have always been the driving force behind our business and these purchases are no different. We look forward to what 2019 holds and seeing how our capabilities are expanded with these additions. Staying on the cutting edge of technology is what makes Hoosier Pattern different and sets us apart from the rest. We take pride in welcoming "out of the box" concepts and making sure that every job leaves our doors with the highest standard of quality. We know these new technologies will help us continue to keep doing great things here inside the walls of Hoosier Pattern.

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

 

Cost Analysis Breakdown of 3D Sand Printing

Calculating the Cost of 3D Sand Printing

In traditional tooling, there are three big points of cost that can make or break a project budget—machining and maintenance, materials, and labor. Each retooling change can add tens of thousands of dollars to overall cost, be it a large design alteration or a small adjustment. Having to wait to find faults in a mold or core after pouring the part in a foundry not only adds to costs, but also adds time you might not have to the frame of the project. A new mold or core will need creating based on an updated design and the process will need repeating until a successful part is produced.

The solution? 3D sand printed molds and cores.

3D printing cuts costs and can help shorten the production process dramatically from what you would expect from traditional tooling methods. Because just one CAD data file is needed to construct a 3D sand printed mold or core, entire steps that would normally be necessary in a traditional process can be factored out. Because of this, economical production is possible with 3D printing, enabling volume to range from individual pieces to small batches of parts.

In 3D sand printed molds and cores, the possibilities in complexity are near limitless—with that complexity also comes an added benefit of cores and molds having potential to be printed in one piece, taking out the entire step of assembly in the overall process and any costs associated with the step.

Our Cost Calculator 

When determining the cost for a core or mold, we typically take the L x W x H dimensions of the to-be-printed piece’s bounding box in cubic inches and multiply them by $0.13. If we don't have to clean the core or mold and can ship it exactly how it comes out of the box, we multiply the amount by $0.11 per cubic inch. Our minimum printing charge is $450.00.

Hoosier Pattern is an industry leading innovator and manufacturer. We pride ourselves in elevating our work and our customers with quality, cost-effective solutions, meaning great castings and quick turnaround times. Contact us today to get started.