HOW HUMTOWN CONSOLIDATED 8 CORES INTO 1
PROBLEM: A foundry had a problem – their project was going to require 8 different cores (!!!) to be produced and then assembled. Not only was this project going to require the production of 8 different sets of tooling and 8 different cores, but it was also going to involve assembly steps that included jigs, fixtures and the gluing together of all 8 components. An assembly this complex was likely going to lead to extensive skilled labor hours and a very lengthy production time. The glue and fit of the cores were also added areas of concern due to the high level of variability and scrap which were inevitable during the casting process. That’s why this foundry turned to Humtown Additive.
SOLUTION: Humtown’s no-assembly cores were a no-brainer for this project. Through our 3D sand printing, we were able to print one core that consolidated all 8 components, completely eliminating all of the assembly that would have been required. For our customer, switching to 3D sand printing…
• Reduced from 8 cores to 1 core
• Eliminated the need for any tooling
• Removed all gluing tolerances Increased accuracy of component placement
• Eliminated extensive skilled labor assembly hours
• Produced a better casting with less scrap
Not only did the 3D printed cores perform better during the casting process, but the cores were produced in 75% less time and for 20% less cost. The higher the level of complexity, the better the case for Humtown Additive. If you are interested in how Humtown’s 3D sand printing can consolidate your cores, click the button below.
HOW HUMTOWN CONVERTED CNC TOOLING INTO 3D PRINTED PARTS
PROBLEM:A Humtown customer had CNC cut tooling produced several years ago and due to the very small 1/8” diameter of the core, the tooling had worn out. To get the core box to fill, Humtown had to increase the blow pressure of the machine, which wears out tooling even faster than usual. Once a core box starts to wear out, either clay or gasket material is used to keep pressure in the cavity, but the downside of that is that loose sand sticks in the material and further damages the tool.
SOLUTION: Humtown proposed creating a 3D CAD model of the core and 3D printing the cores instead. Not only that, but they would print the cores in a box that could be shipped straight to the foundry. To date we’ve produced over 10,000 cores using this 3D solution and the customer has seen improved casting yield, lower scrap in shipping, and found an added bonus that the 3D printed cores clean out better from the casting! If you are interested in converting traditional, worn out tooling into 3D printed parts, click the button below.
HOW HUMTOWN TURNED A SCRAP JOB INTO A PRODUCTION JOB
PROBLEM: A foundry and their OEM customer were frustrated. They had spent all of this time and money cutting all of the tooling for three highly complex engine components, but they kept having to scrap the castings. These three cores were so intricate and the assembly was so complicated that even after spending significant time manually gluing each component into position, they still had to scrap most of their castings. Out of time and running low on patience, this foundry needed to find a solution, and find one fast.
SOLUTION: Quickly running out of options, this foundry contacted Humtown Additive. However, they had trepidations about the volume of parts they could produce. They had heard 3D sand printing was great for prototyping, but not for production. They quickly learned they were wrong.
This foundry sent their design files to Humtown Additive, and we were able to 3D print these three core designs as one core. This core consolidation eliminated all manual assembly – and the time and cost associated. Eliminating manual assembly also led to 0% scrap rate, an astounding statistic when you factor in the complexity of the piece. And their production fears were put to rest as Humtown Additive went on to produce tens of thousands of cores and molds for this customer. If you are interested in series production orders, click the button below.