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.
With the school year back in full swing, we wanted to give some recognition to our summer intern, Lucas! Lucas spent the summer at HPI shadowing different departments and even desiging his own part. Lucas is 18 and now a Senior at Bellmont High School. Get to know a little more about Lucas and his experience at HPI below.
How did you get connected with HPI? Did you pick it or were you placed here?
I applied to Connexus online and HPI chose me to interview and then picked me to be their summer intern
Did you have an interest in what HPI does before you interned here? Do you have more of an interest now?
Yes, I was interested in CNC machining and 3D printing and now that I have learned as much as I could in 6 weeks about them, I am more interested in HPI.
What type of things did you do at HPI?
I shadowed someone from each area and I learned a little bit about everything. I got to design and make 2 different projects as well.
What did you enjoy the most?
I enjoyed making a plate with a tractor on it and then designing a scaled down break rotor that I got to pour and cast.
Did you learn some new skills during this internship?
I learned how to work a new software and also how to melt down and pour molten metal.
How would you describe the atmosphere?
Everyone was friendly and more than willing to answer all of my questions.
Did it change/inspire any future career plans?
It inspired me to keep continuing on the path of engineering.
Would you recommend an internship or job shadowing to other students?
Yes, because I learned a ton of things this summer through the program and it gave me a taste of what the real world is like.
HPI enjoyed having you this summer and we are confident with your willingness to learn and grow that you are going to do great things! Have a great school year!
Jim Geimer has technically been a Journeyman Patternmaker since May of 2018 but after a couple delays, HPI finally got to present him with his official state certificate that certifies him as an official Journeyman Patternmaker! Jim started at Hoosier Pattern in February of 2012 and officially entered the apprenticeship program in January of 2013. Over the next 5 years, he logged 10,000 working hours along with taking the required 12 classes at Ivy Tech Community College. He wrapped up his apprenticeship in early 2018 and as of this morning, his certificate is officially hanging on our wall!
All Hoosier Pattern employees as well as Jim's wife, Stephanie, were there for the presentation.
Congratulations Jim! We are so proud of you and can't wait to see the great work you do in the future.
Hoosier Pattern prides itself on being innovative and consistently raising the bar within the industry while maintaining the level of quality they are known for. Back in 2013, Hoosier was the first top service center to own and operate their own 3D sand printer in the United States. Coming Summer 2018, Hoosier will be the only service provider to own and operate two 3D sand printers under their roof along with maintaining a 3rd printer in their facility as well.
Customers are the driving force behind everything Hoosier does and this expansion is no different. This will allow Hoosier to take on jobs that once had to be turned away due to capacity restrictions. The current turnaround time for printed sand of 10 days will remain standard; however the possibility to turn printed parts around sooner -if needed- for customers has greatly increased.
On top of the addition of the 3rd sand printer in house, Hoosier has recently added a 5-axis machining center as well as 3 Doosan DNM 650’s to the machining side of the shop. All of these additions allow Hoosier to maintain current customers as well as take on new customers with more complex projects.
Exciting things are happening at HPI. Stay Tuned!
Recently, the Area 18 Precision Machining class at South Adams High School poured their own castings from 3D printed molds printed with HPI’s sand printers.
The South Adams / Area 18 Precision Machining classes prepare students for going straight into their machining careers. Several of our employees at HPI are graduates of this class. Past graduates include Tony Uhrick, Ryan Seddlemeyer, Phillip Bauman, Jon Dathe, and Kyle Rittmeyer. Advisory board members from Hoosier Pattern include Keith Gerber and Ryan Seddelmeyer, and Todd Yoder.
The graduates of this class can earn both NIMS (National Institute of Metalworking skills) certifications and college credit, but most importantly, they are ready to begin their careers in a real-world machining/manufacturing company.
The South Adams Precision Machining class begins the first year with an introduction to shop safety, shop math, and basic hand tools. While the first “bench work” project is starting, each student gets an introduction to CNC (computer numerical controlled) machining by using a CAM system to design and program a polished aluminum nameplate for their lockers. After that, it is back to the manual machines to get a good machining foundation on manual lathes, mills and surface grinders. By the end of the first year, the students begin to get more experience programming and setting up basic parts on their 6 CNC machines. (3 of the machines were donated by HPI).
During the second year class, students completely design, engineer and manufacture a complex assembly from scratch. This year, the student designed a double acting steam engine with variable timing. The students worked together as a team to produce a working model in SolidEdge of their own design. Once the design was finalized, the students created industry level blueprints for each part along with inspection sheets. After that, the students will take all that paperwork they created as a team and machine all the parts individually and leave with a working engine by the end of the school year. The column/crankshaft support is the part that the students worked with HPI to have sand printed molds made for.
Back in January, Mr. Jerod Dailey’s class poured their castings using HPI’s molds. Lars, Mason, Chandler, Keaton, Kegan and Bailey got some real hands on training in handling molten aluminum as well as how to safely pour it and produce a quality casting. Below are some pictures of the class as well as some of the student’s thoughts on the project.
1st and 2nd are of the parts they poured – there are two parts to a pour, each one will make a column for the 17-18 engine project that the students designed. Once they are cut apart, there are still 4 holes and 2 bearing bores that will be machined.
The material that they melted that was donated by FCC Adams and they used about 8 pieces for this first pour. 4 more pours to go plus any green sand casting they do. The class took their scrap parts and cut them into 4 pieces to fit in the crucible
Last picture are the molds that Hoosier Pattern made for us with the 3D Sand Printer
“It was really interesting to pour molten aluminum. It was neat that at really high temperatures that metal will flow as easy or easier then water. I thought it was going to be pretty light weight but when all the aluminum was melted it was actually pretty heavy. So thank you for the material and for donating the molds to us so that we could experience casting for the first time."
Keaton A. (Adams Central)
“Pouring our molds was very interesting and fun because we got to see the aluminum melt and turn into liquid form which I have never seen. This was my first time I have ever poured aluminum and I think it would be cool to do more often. Thank you for donating the molds to the class so we could have the opportunity to pour our own part for our class project.”
Chandler S. (Adams Central)
“Thank you for the molds that you made for us. This was the first time I have poured aluminum and it was one of the coolest experiences I have had in this class. I was surprised by how easily it poured into the mold. I hope I can defiantly do this again sometime.”
Lars I. (South Adams)
After 41 years in the industry and 4 years at Hoosier Pattern, Steve Murray is retiring at the end of this year. Steve has played a vital role in the sand printing portion of our business here at HPI. Steve didn't have a desk in the building, instead he could be found speaking at events, shows and meetings representing Hoosier and getting our name out there within the industry. A short interview with Steve below gives insight to his years as a patternmaker.
Badges from various shows/events Steve has been to representing HPI
How long have you been in the industry?
Since 1976 and joined the Patternmakers League of North America a short time later. Since then I have had the privilege and good fortune to work in many pattern shops and foundries. I liked moving around to learn new things and experiencing different manufacturing methods and products. You learn so much from others and everyone can teach you something if you are open to the experience.
What attracted you to this industry?
Making things. Most manufactured things, products, parts or whatever you want to call them started out in a pattern shop or model shop. All these designs were funneled through these shops. To be in one meant you had a wide and varied list of things you would be required to make, so boredom was not an issue. Just think of all the parts that make up an automobile, plane, ship or household appliances, industrial machinery and many other categories of parts that needed to be manufactured and they all started with a guy making something. I wanted to be that guy. The guy who was the first to make this type of engine block, head or bracket. How cool is that, to make the first of something on planet Earth, or to make something that future archeologists will dig up and marvel that we back in the day had the technology to make this or that. They always dig up metal bits and put them in museums and such. So, I like, I get a kick out of making things. Always have and most likely always will.
Do you have any advice for people wanting to get into this industry?
The industry needs you and wants you. If you like hands on learning, practical learning and not all the fluff, then jump in. Yes you get dirty, but all of us clean up good, and working with your hand and your mind is the best combination there is. This industry is what you make of it, much like life….what you make of it. All the skilled trades are cool professions. Yes, profession, not job. You master a skilled trade, you are by definition a professional. There is a pride in that, no one can take that away from you and you are that professional till you die.
How has the industry changed since you started?
Technology. A skilled hands trade has evolved to a skilled technology trade. Skilled hands are still required but technology has let one skilled tradesperson replace a dozen from years past. My past which to me is not all that long ago, but to younger people it is ancient history. The speed at which things are done is remarkable. The knowledge and use of such a wide variety of technologies is astounding. Technology changes in Chemistry, Material Science, IT, Simulation and on and on are impacting the industry and it keeps making this industry interesting.
Last week, Hoosier threw a retirement lunch for Steve and surprised him with a bronze statue as a retirement gift. Something people may be surprised to know about Steve is that he is a very talented wood carver. He initially carved the body of this statue out of wood, we scanned it and already had a 3D file of Steve's head. We combined the two CAD files and with some help from Artcast Inc. in Canada, ended up with a fantastic casting.
What are you going to do with all of your free time now?
Carve/sculpt or make things just because I want to or because I think they are pretty. I will draw and paint more and also work making my gardens. I love to garden and I hope to finish my 5 acres of garden beds before I leave the top side of this Earth. On the family side, I want to have those days with my Miss Judy that we have been waiting for all these years. Enjoy each and every one of them together.
What would people be surprised to learn about you?
That I am a home body who likes to cook for my Miss Judy and that I enjoy more solitary activities. If left to my own devises I could be a hermit, but my Miss Judy keeps me engaged with the world.
HPI wants to thank Steve for his many hours of traveling, sleeping in hotel rooms, eating airport food and for ultimately representing Hoosier Pattern in the best way possible. Steve's knowledge and passion for additive manufacturing helped give HPI a head start within the industry, which is invaluable. Steve, we want to wish you a very relaxing and worry free retirement. You have earned it.
This morning was a busy morning as HPI welcomed TWO new machining centers to add to the list of equiptment we have in our facility:
Mazak Veriaxis 730-5X ii * 5 axis machining center
Travel: 28"x33"x22" *Large work area for a 5 axis machining center
Pallet changer *for light production and multiple setups
With a 5 Axis HPI's possibilities are endless. It will help throughout the shop but the rigging department might benefit the most. With this machine we will be able to do the same as eliminate the super long reach tools that have become a standard around the shop. It will help us to be more aggressive on quoting very complex jobs and taller jobs with tight reach areas as we will be able to utilize shorter tools to perform the job. So long story short: We will be able to complete higher complexity jobs faster and better than ever before.
Doosan DNM 650
Doosan is a new face around HPI. We are looking to capitalize on the advancements in the cutting tool world with machines that can accommodate the speeds and feed needed to utilize these tools to their fullest. With the profit margins shrinking in manufacturing market, we are looking to produce the high quality foundry tools HPI is known for in a shorter amount of time.
It feels like Christmas came a couple days early for Hoosier Pattern. We are excited to see how these machines are utilized for our customers projects and look forward to putting them to good use.
December 7-9 the 30th annual Performance Racing Industry show took place in the heart of downtown Indianapolis at the Indiana Convention Center. Attendees at this show discover the latest in machining and automotive technology as more than 100 manufacturers and over 1100 companies total showcase their latest developments in auto racing technology.
Ryan Seddelmeyer, Alyssa Corral, Dave Rittmeyer and Brandon Fourman all represented HPI in Indy networking with existing customers as well as potential customers. Custom castings for automotive projects is where Hoosier shines at this show. The possibilities potential customers think of when they think about incorporating 3D printed sand into their restorations, remodels and other projects are endless.Hoosier's booth featured 3D printed sand cores and molds as well as some 2 stroke cylinders, cylinder heads, a mini v8 engine block and of course, our mini pouring man casting that goes with us to every show.
This year for the first time PRI had a Featured Products Showcase. Hoosier entered the mini v8 engine block casting as well as the 3D printed sand mold that it was cast from. Attendees saw the pieces in the showcase and came to HPI's booth to ask questions and inquire about their future projects making the entry into the featured products showcase a huge success.
Last year during PRI 2016, Hoosier met an entrepreneur looking for an FDM printed prototype. HPI took on his project with their Stratasys Fortus plastic printer and helped get his idea off the ground. This year at PRI 2017, he came back with 2 Never Measures in hand as gifts for HPI employees as well as the exciting news that he officially launched and started selling them last week. HPI is currently working with the crew at Never Measure on an article for a more in depth look about how this project came to life. Until then read more about the Never Measure here.
Thank you to everyone who stopped by booth 5036 this year. If you stopped by and are interested in more information about HPI's capabilities or want some 3D printed sample molds click here. Next week, Hoosier will be in Houston, Texas at the Turbo and Pump Symposia.
In November of 1997, Hoosier Pattern consisted of 3 employees in a 4600 sq. foot area with 4 machines: 1 vertical CNC machine, 1 manual bridg port, 1 manual lathe and 1 welder.
Over the last 20 years Hoosier Pattern has gained recognition as one of the region's premier pattern shops as well as a becoming a leader within the industry. In 2013, Hoosier purchased a 3D sand printer and at the time it was the largest 3D printer in the United States. With the addition of the 3D sand printer in HPI's toolbox, Hoosier was elevated to a new level of manufacturing. Not only could the HPI team build you a tool for high volume production, but they could also help out with low volume production or even prototypes.
Present day, Hoosier currently employs 42 people in a 80,000 square foot facility. Hoosier houses over 20 machining centers including: vertical machining centers, horizontal machining centers, 2 CNC lathes, 2 EDM's a manual CMM, and a laser scanner. They also house 2 ExOne S-Max™ Sand Printers within their walls as well. Hoosier offers an apprentice program that is registered with the United States department of labor and offers internships and job shadowing for current students interested in the trade. Congratulations on everyone at Hoosier Pattern for celebrating this milestone anniversary!
As of July, Hoosier officially has a new Journeyman Patternmaker to add to our already impressive list of skilled employees. Phillip Bauman completed his 10,000 work hours and classes at Ivy Tech Community College over the past 5 years and received his Journeyman Certificate from the Indiana Department of Labor last week.
Phillip Bauman has been a part of the Hoosier Pattern family since May of 2012 when Keith hired him at the end of his senior year of high school. Phillip was initially hired to paint the outside of the building. One day it had started raining and Keith told Phillip to come inside and shadow some of journeymen already out on the shop floor for the day and he has been here ever since. Phillip is currently one of our CAM programmers and occasionally can be found in the Hoosier Pattern booth at some of the trade shows we attend.
Congratulations, Phillip! Your hard work and dedication to Hoosier Pattern over the past 5 years has been truly appreciated. We are proud of your work ethic and are grateful to have you on our team.