Pure Power F
Eyes Growth in Lost Foam
With three years and $1.5 million invested in its lost foam operation, Navistar’s Pure Power Technologies in Waukesha, Wisconsin, focuses on building interest from its parent company and external OEMs. NICHOLAS LEIDER, ASSOCIATE EDITOR
our years ago, Pure Power Technologies’ facility in Waukesha, Wis., began its
transformation from a captive green sand operation for Navistar Inc. into a hybrid that also would focus on devel- oping business from other OEMs. Te goal then, as it remains today, was an even 50-50 split of orders from its par- ent company and external sources. In an effort to broaden its appeal to both sides of its business, the Wauke- sha facility acquired the necessary equipment to begin lost foam casting production in November 2010. Tree
years later, Pure Power executives see the $1.5-million investment entering a phase of expanding its capabilities and accepting more orders for production parts. While lost foam, with a total capacity of 10,000 tons annually, will remain a smaller portion of the facil- ity’s 50,000-ton capacity, its addition signals an emphasis on diversifying capabilities. “Lost foam is a technology that
allows us to make parts we can’t produce in green sand,” said Mitch Cheatham, general manager. “It allows us to offer a wider variety of products
to our customer base and to interact with customers who we wouldn’t necessarily be able to with just a green sand foundry.” Pure Power bought a production
lost foam molding line in 2010 from a metalcaster that was closing its doors. It consists of ceramic coating equip- ment, a conveyor system, a vacuum system, a compaction unit with sand silo, casting and sand retrieval, sand cooling and handling, and a shot blast unit. Since its installation, the company has successfully produced more than 50 parts with diverse geometries from 8 to 260 lbs. While Pure Power continues its path of process improvement, an increase in larger production orders remains a goal for the next two years. “Right now, we have developed a
wealth of lost foam processing knowl- edge and we recognize that there is still more to learn. It’s a new process for us,” Cheatham said. “Our focus is twofold. In addition to produc- tion casting, we use it extensively as a method of rapid prototyping. We can turn around prototype parts in as fast as a week. Tat’s a niche market we’re focusing on. “Additionally, we’re looking for
Pure Power initially purchased the lost foam equipment in late 2010 and began production in May 2011. 24 | MODERN CASTING December 2013
partners who are willing to go into a development process, who are willing to give us the time to methodically
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