“
Decisions made during the casting design process have far-reaching consequences.”
casting can be additive or subtractive, by printing a foam block or CNC machining pieces to be assembled into a pattern. Prucha off ered an example of an assembly consisting of eight fab- ricated parts, which is now produced as one lost foam casting produced by CNC machining the foam patterns. Subtractively CNC machining sand molds—another rapid method to produce ready-made molds for casting without tooling—off ers advantages when producing a very large part. Sand binder-jetting equipment is limited in size and takes time to build up large layers, incurring additional cost. In addition, sand mold and core material composition is more fl exible with sub- tractive methods, which can be a key benefi t when using certain alloys. Additive manufacturing options
involving 3D metal printing are lacking in scope for metalcasting pat- terns, coreboxes and tooling, accord- ing to Prucha. “Eff orts are underway to create smaller pieces, but print size, part density and the types of metal that can be deposited currently limit its use,” he said. A single company probably won’t
have all of the available technology, choosing instead to specialize in one or two areas. But, there is a tendency toward collaboration among casting suppliers providing rapid solutions, as well as jobbing out to one another.
The Benefi t for Buyers For original equipment manu-
facturers (OEMs) buying castings, rapid manufacturing off ers a variety of benefi ts. Design and engineering ideas that were not always possible can be realized. T e precision of ad- ditive methods in particular enables feats of draft and wall thickness that have not been possible in the past. For metalcasters running auto- mated lines that are cost-prohibitive for prototyping, rapid methods can
be used to make molds that fi t into that equipment for a trial run. Rapid methods also are being used to make production pattern equipment for longer runs. While prototyping doesn’t always have stringent demands in early design stages, often the parts are made as close as possible to the versions that will be cast in full production. Prucha recommends an integrated
approach to rapid manufacturing using computer-based technology. “[It] not only reduces lead time but improves the design,” he said. “T is should be managed via a disciplined program management system. Technologies that assist in creating
samples quickly will help maximize the evaluation time and decisions made during this critical phase.” Rapid manufacturing enables
metalcasters to produce components for physical testing that match the castings to be created in full produc- tion using other methods. It’s a game changer in the market’s ever increasing competition to produce lightweight, high performance components. “I was at one of the bike shows and a lot of people were intrigued with us using the latest suspension,” said Hanegraaf. “We were mount- ing up the fork itself to the triple clamps. T at bodes well from a marketing standpoint to have those highlighted areas, to show people the days of old versus what we’re ca- pable of doing now.” He credits his relationship with Craft Pattern and the shop’s introduction of 3-D sand printing as key enablers to the proof of concept and straightforward pro- duction of this Polaris prototype.
CASTING RESEARCH CONTINUES ON ADDITIVE MANUFACTURING
America Makes, the National Additive Manufacturing Innovation
Institute, has awarded research funding to the Youngstown Business Incubator (YBI), Youngstown, Ohio. The project, “Accelerated Adoption of AM Technology in the American Foundry Industry,” will be conducted in partnership with the American Foundry Society, ExOne, Humtown Products, Janney Capital Markets and the University of Northern Iowa. Its intent is to support the transition of binder-jet additive manufacturing to small businesses in the casting industry by allowing increased access to use of the equipment and the development of design guidelines and process specifi cations. The institute is a hub in President Obama’s new National Network
for Manufacturing Innovation. Driven by the National Center for Defense Manufacturing and Machining (NCDMM), America Makes will provide $9 million in funding toward this and 14 other projects, with $10.3 million in matching cost share from the awarded project teams bringing the total funding to $19.3 million. “[This] exemplifi es how our incredibly innovative and active commu-
nity comprising both members and non-members is working together, sometimes even with competitors, to advance our industry by exploring the limitless possibilities of 3D printing,” said Ralph Resnick, founding director of America Makes and president/executive director of NCDMM. The project is getting underway as this issue of Metal Casting Design & Purchasing goes to press.
May/Jun 2014 | METAL CASTING DESIGN & PURCHASING | 33
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