Using its rapid tooling method to pro- duce a roof frame casting significantly reduced Acuity Brands’ lead time on a new product.


printer could be the key. “I am always looking at differ-


ent technologies and ways to try to improve products and processes for Acuity Brands,” Davis said. “Don’t get locked in by what you know to be feasible.” Davis’ vision was helped by Acuity


Brand’s metalcasting facility asset in Matamoros, Mexico. T e lighting manufacturer, which produces prod- ucts under several diff erent brands, purchases castings from around the world. It also owns and operates the sand and permanent mold casting fa- cility in Mexico. It is there that Davis learned the ins and outs of casting and tested his rapid tooling idea. “When I came to Acuity, all the


welding and machining was second nature to me, but it was the fi rst time I played with castings,” he said. “I went to our foundry in Matamoros to see what casting is fi rst hand and was trained pretty quickly.” When Davis fi rst broached the idea of using the 3D printer to produce


Nov/Dec 2012 | METAL CASTING DESIGN & PURCHASING | 23


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