O
Rapid manufacturing enables
nce an experimental field, with some play- ers excelling while
others succumbed to economic pres- sures, rapid manufacturing is hitting its stride. Additive 3-D sand print- ing technology enables the produc- tion of quick-turn metal castings for applications ranging from proof-of- concept prototypes to high quality preliminary runs and onward into full production. For metalcasters, the benefits of using this flexible design method are impressive. When Polaris Industries, Medina,
Minn., was evaluating ways to improve its Indian “Big Chief Custom” line of motorcycles, metalcaster Craft Pattern & Mold, Montrose, Minn., proved itself a key player. One structural component in
metalcasters to produce components for physical testing that match the castings to be created in full production using other methods.
the redesigned girder style sus- pension system achieved a 30% weight savings through conversion to metalcasting. Typically a steel fabrication, the part is a prototype of the upper triple clamp for the front steering assembly on the motorcycle. “Te use of high strength alumi-
num alloy allowed for critical weight savings, a key driver of performance in the motorcycle industry,” said Tony
Cremers, president, Craft Pattern & Mold. “Te cast aluminum design is much lighter. Also, the shock mounts and the pivot arms tie in with it, so it’s incorporating three things into one component.” Other noteworthy benefits to
casting the part was Polaris’ ability to incorporate its logo directly into the part, as well as the part’s better appearance overall.
A suspension component designed using rapid prototyping was a key improvement to the Polaris Industries Indian “Big Chief Custom” motorcycle. July 2014 MODERN CASTING | 39
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