PRINTING
ternmakers and casting users have started using 3-D equipment to build, layer by layer, sand molds and cores to pour sound, produc- tion-quality castings. Te method has been cutting weeks out of product development lead times, reducing costs and, in some cases, achieving designs that defy traditional production constraints.
S “[With additive manufactur-
ing] we are able to manufacture that which we haven’t been able to make before,” said Steve Murray, an independent sales/marketing liaison for Hoosier Pattern, Decatur, Ind., which uses an in-house printer to make sand molds and cores. “If that doesn’t get you excited, then get out of the business.” While direct printing of products
like an acoustic guitar, stylized clock, nylon bike or smartphone case makes headlines, secondary processes such as metalcasting could have the most to gain from additive manufacturing. “Te conversation in the media is
focused on the production application of saleable goods, but honestly, it’s not likely an option for the average com- pany,” said Todd Grimm, a 23-year veteran of additive manufacturing
and industry advisor to the Additive Manufacturing Users Group. “I see a lack of attention in the media on the product development side, but making models and prototypes is a strong area. Plus, we are seeing some new ingenu- ity and creativity in applications we haven’t seen before.” Te investment casting industry has been using 3D printing since the ‘90s to generate patterns for low run or prototype parts. Sand printing brings similar advantages to sand cast production parts. Engineers can pro- cure prototype parts they are assured accurately reflect how the parts will perform in full-scale production. In some cases, the printed mold or core is used to manufacture castings beyond the trial period because of the com- plexity of design that is achievable or when it is a low volume order. “Time compression is just one
POSSIBILITIES
Emerging additive manufacturing technology for sand molds and cores removes design constraints and accelerates speed to market. SHANNON WETZEL, SENIOR EDITOR
till relatively young, additive manufacturing is gain- ing traction as a rapid prototyping/manufactur- ing technique, but it is not relegated only to direct production of a saleable good. Metalcasters, pat-
advantage of additive manufactur- ing ,” said Jerry Theil, director of University of Northern Iowa’s Metal Casting Center, which recently installed a 3D sand printer at its facility in Cedar Falls, Iowa. “Flex- ibility also comes to play because we don’t have to obey conventional molding rules such as draft.”
Reducing Tooling, Time to Launch John Deere has been utilizing)
additive manufacturing for sand molds and cores since 2011 as part of an effort to decrease spending on prototype tooling in product develop- ment. Enterprise-wide, the company spends about $100 million annually on feasibility and prototype castings. Te ability to test several design iterations without investing money in hard tool- ing, coupled with the ability to achieve desired intricacies with fewer cores, makes the rapid casting process an attractive option. “We have found different paths to
choosing additive manufacturing for a part,” said Sheila Dickey, manager of technology integration at the Casting Center of Excellence for John Deere Foundry Waterloo. “To determine if the process is applicable, we consider whether it requires a short lead time or if the casting design itself is so complex that we could print a single core on the printer as opposed to
December 2013 MODERN CASTING | 29
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