at the workstation. Critical to this step was the quality of the sand. Knowing this, TEI turned to AFS Corporate Member Hoosier Pattern (Decatur, Indiana) to produce the two 3-D printed molds. “It was vital that we had really good sand that could be cleaned easily,” Johnson said. After cleaning, machining was

another challenge. “Tere were only three areas to

machine, but the part isn’t easy to hold or access,” Johnson said. “While were working on the mold design and casting the part, in parallel we were designing and machining a fixture.” TEI used simulation to map out

the entire manufacturing process of the swingarm, including machining. Te prototype mapped out the whole machining operation in a virtual simu- lation that simulated the cutting tools, fixtures, and the motions of the pallets. “Everything is simulated because

you don’t want to have a mess up on a job like this,” Johnson said. Te simulation paid off. Te two molds both produced good parts, cleaning was successful, and machin- ing operations were completed with- out a hitch. After CT scanning, white light scanning, x-ray inspection, and dimensional checks before and after heat treating, the swing arm was ready for the customer within the three- week deadline. “One of the reasons this has been

such a strong collaboration is TEI is an early adopter and strategic user of technology, particularly in simulation technology,” Bastian said. “Te casting coming out right the first time was pretty phenomenal.” Te success of the cast swing arm will help Autodesk further make a case for

The swing arm was designed for the Lightning LS-218 motorcycle.

applying generative design to not just metal printing but also metalcasting. “Metal printing likes to show

all these exotic shapes that can be produced, but we want to demonstrate casting is a technology that is quite well suited to those shapes, particularly when you are making something larger than a bread box,” Bastian said. “Met- alcasting offers hundreds of materials to choose from compared to metal printing, and the manufacturing base is mature.” Kahaian agrees and is excited for

the future of metalcasting as the adop- tion of additive manufacturing in the industry speeds up.

“3-D printed sand is a cheap medium to print in, and it’s using the same materials we have been using for hundreds of years,” he said. “It’s unlimited in size. It is the future, and realistically, there are no boundaries.” Designs like the swing arm are great

showpieces, but Johnson believes the impact can go past the exhibit floor. “You might not see parts like the swing arm on a mass-produced vehicle, but you could apply the same approach of optimized design,” he said. “Te part may only look subtly different but it still can be optimized with the appropriate constraints of conventional technology.”


Te annual Casting of the Year competition is sponsored by the American Foundry Society and Metal Casting Design & Purchasing magazine and recognizes excellence in casting design. Te competition is open to all North American metalcasters and designers/end-users of metal castings. Castings are accepted in all metals, casting process, end-use applications and sizes.

MEDIA RESOURCE To see a photo gallery of the

excellent casting designs honored in this year’s competition, visit

Independent judges evaluate each entry on: • Benefits delivered to the casting customer. • The use of the casting process’ unique capabilities. • Contribution to growth and expansion of the casting market.

May 2018 MODERN CASTING | 31

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