Rapid growth makes way for

focussed future

Following a storming acquisition trail where more than 200

companies were brought into the family, Japanese giant
ARRK has reassessed its business strategy to bring a more
unified approach to its world-wide business emporium. The
global product development specialist was particularly keen
to take advantage of the huge potential for synergies in
its European companies and the UK stood out as an area
where improved co-ordination of services would elevate the
company to increased future success.
The newly named ARRK Europe Ltd will see the UKs four separate group
companies, on seven sites, brought together with a unified management
structure and operating as specialist divisions of one entity. ARRK R&D Ltd
(Basildon) and NPL Technologies (Nuneaton) merged in April with ARRK
Product Development Group (Gloucester) and ARRK Tooling (Petersfield)
due to join suit later this year.
The managing director of ARRKs UK operations, Tony Lowe, says the
move signifies a joined-up thinking approach giving customers an improved
route to tap into the groups many different specialisations. Customers
will have access to the whole range of services, giving them much wider
possibilities for a one-stop solution. They can continue to access these
services through their local contact or they can go direct to the relevant UK

division specialising in what they need.

There are huge potentials for synergies and the
customer now has access to everything from design
through rapid prototyping to low volume production
of parts in one company. It offers great advantages
to our employees with a strong sales force, sector
specialists, industry and technical specialists and
excellent IT integration. There are other companies in
the global group which offer higher volume production
and this can be supported by ARRK Europe.
As part of the move the Gloucester facility will
remain as the companys rapid prototyping technical
centre, a badge it has worn well for many years
following continued investment in the latest RP
technologies and equipment. PU mouldings and
precision castings will also be produced at Gloucester
which has built a reputation within the group for fast
response rates. Craig Vickers, managing director of
the RP division said: We tackle about 1,000 quotes
a month and all are dealt with within 24 hours,
most within eight and a good number within four
customers expect a quick answer. This dynamic
approach is fundamental to ARRKs success and the
companys ability to respond to growing customer
needs for advanced solutions.

A material world
Selective laser sintering (SLS) has been the biggest
growth area in the industry in the last five years and
it has accounted for some of the major investment
at ARRK. The companys engineers are continually
evaluating new materials and adding them to the
range of glass filled nylon, duraform and PA already
on offer. EX and HST are two such materials recently

114

FTJ May 2010

incorporated into the mix. EX combines durability

with flexibility. HST builds on the characteristics of
glass filled nylon but with even greater strength and
temperature resistance. Water clear SLA resin gives
a glass-like appearance and is often the material of
choice for designers. Prototype parts can be delivered
in as little as two to three days.
Reverse engineering using 3D scanning has also
grown in popularity, particularly where the original
CAD data is no longer available and ARRK unveiled
its new 3D scanning service last year.
There are 13 SLA machines at the Gloucester
site and a choice of materials (e.g. ABS simulant,
watershed resins, clear and white resins) is available,
again parts can be delivered within two to three days
of receipt of CAD data
Using an SLA master to create a silicone mould,
epoxy tooling, silicon skin and plaster moulds, exact
copies of a part can be produced for consistent
quality. Vickers said: The design can be checked
quickly to make sure its correct and its a much less
costly and time consuming option than diecast tooling.
This process can certainly compete with high pressure
diecast parts up to 1mm wall thickness.
The Gloucester employees are particularly proud
to be the only company in the group with their own
in-house foundry where RP techniques are used to
cast low volume runs of precision aluminium and zinc
components to a minimum wall thickness of 1mm.
In-house CNC machining means components can be
machined from solid or castings produced in-house
can be post machined.

The Gloucester site is quite literally pushing the boundaries having filled
every spare corner with the latest technology to drive the business forward.
Enthusiastic staff under the watchful eye and long distance support of the
Japanese parent company means ARRK Europe is well placed to continue
its growth rate but in a more unified and structured manner. Its an exciting
time for ARRK Europe and its customers. Fragmentation associated with
a large world-wide group has been avoided and activities in the European
market are now focussed and integrated the fine tuning is yet to come but
the signs are looking good. It seems ARRKs sun also rises in the West.
ARRK Europe Gloucester Technical Centre, Unit 11 Olympus Park,
Quedgeley, Gloucester GL2 4NF United Kingdom. Tel: +44 (0) 1452
727700, email: projects@arrkeurope.com web: www.arrkeurope.com

Supporting front line action

ARRK recently worked with
Kent Periscopes on the
development and low volume
production of periscopes
for military fighting vehicles
using its rapid metal casting
service.
Time was of the essence
so a team from ARRK was
able to quote for the supply
of 25 castings in aluminium LM24 within a few hours of
receiving the specification, offering a delivery time of
three weeks. The client specification requested that the
components should have inserts and be supplied in a
finished condition including alochrome and paint possible
thanks to ARRKs in-house paint and CNC departments.
In accordance with customer needs, the components were
sprayed with special non infrared detection paint.
The company says its wide range of in-house services
means the customer saved valuable time and effort by
not having to source services from different suppliers and
was able to complete the project with one contact point.
Such was the satisfaction; the customer has continued to
use ARRK for its low volume production needs. The initial
requirement of 25 castings has grown into several hundred
parts.
ARRKs rapid metal casting service can be used for
prototype and low volume production of aluminium and zinc
castings needed in a hurry.

FTJ May 2010

Our Foundry Support services could

help you save time and money!
ARRK offers foundry clients a wide
range of support services.
SLA Quick Casts replacing the need for wax patterns
Prototype Metals Castings in Aluminium and Zinc
to verify your casting
Low volume to bridge to production runs
Post CNC machining, Painting and Finishing
ARRK can accommodate thin wall sections as low as 1mm.
Contact: Dai Kinman, on 01452 727770
or email: projects@arrkeurope.com

www.arrkeurope.com
115

Rapid protyping

Aluminium components make the electric car lighter and safer

The design and construction of an electrically-powered concept
vehicle called Light car-open source is underway with cast
components, developed through rapid prototyping, an important
part of the process.
Engineering service provider EDAG built the car together with partner
companies in the supplier industry and presented it at the Geneva Motor
Show in March this year.
Light aluminium structural components from Honsel in the chassis and
bodywork reduce the electric cars weight; they weigh around 40% less than
comparable components in steel.
For the light car-open source, Honsel is supplying a number or items
including: parts of the spaceframe, all chassis and suspension parts and the
front crash structure. These components consist of light aluminium extrusion
profiles. The subframes and front and rear suspension arms, for example,
are in cast aluminium, as are the connecting links for the extrusion profiles
and the B-and C-pillars.
For electric vehicles like the light car-open source, light engineering
is especially decisive; to compensate for the high extra weight of the
batteries, the vehicle structure needs to be extremely light. But weight-saving
aluminium and magnesium components also offer significant advantages
for conventional cars. The reason is the planned high penalty tax for cars
that consume too much fuel and CO2. With our innovative light engineering
solutions we offer the right answer to the challenge facing the automotive
industry of making vehicles ever more economical and clean, said Dr
Heinrich Fuchs, head of materials and process development at Honsel.
100kg less vehicle weight means up to 25gm less CO2 emissions. Installed
at the right places in the car, light metals can also achieve the same crash
safety as steel components, so they offer two advantages at the same time.
Since development of the light car-open source began, experts from
Honsel have worked closely with specialists from the partner companies
involved. Honsel, for example, has supported the engineering of the
aluminium components and taken over the casting-specific design. It took
only three months from the first drafts to the finished components. With our
extensive know-how in rapid-prototyping, we were able to realise the project
in the shortest of times. Despite the fact that the light car-open source is a
concept car, all components were optimised to the high standards for weight,
strength and crash performance in large series production, said Dr Fuchs.
The B-pillar of especially thin-walled cast aluminium, for instance, has a load-

116

bearing function for the bodywork, effectively protects

the passengers in the event of a side impact and is
also extremely light.
Honsel has already developed the casting methods
needed to cast components such as the B-pillar in
aluminium in series production and is almost ready
to do so. Experts estimate that 50% more light metal
components than today can be used in the suspension
and vehicle structure in the medium term. In this
context, the right materials mix of steel, light metals
and possibly fibre-reinforced plastics is crucial. The
right material at the right place - that will be the
engineering concept for the light, economical and
clean vehicles of the future, predicts Dr Fuchs.
Spaceframe bodywork structures in light metal
from the company are already successfully in series
production today. A spaceframe is a frame of hollow
aluminium profiles linked at their connecting points
by cast components. In the chassis area, the rear
axle support from Honsel in cast aluminium for the
Volvo XC 90 now weighs in at only 23.5kg - it saves
around a third of the original weight. Whilst the engine
support of the Peugeot 407 as an aluminium structural
component weighs a mere 15.5kg.
Honsel is one of the world's leading producers of
light-metal components with primary focus on the
automotive industry. The company develops and
manufactures aluminium and magnesium products
using the casting, extruding and rolling processes
for engine, transmission, suspension and body in
passenger cars and commercial vehicles.
Founded in 1908, Honsel has become a
development partner and systems supplier for the
worldwide automotive industry and has facilities in
Germany, France, Spain, Brazil and Mexico. About
4,000 employees now achieve a total turnover of over
700 million.
www.honsel.com

FTJ May 2010

Rapid protyping

Rapidly flying higher with prototype engines

A leading specialist investment casting foundry has developed
a rapid prototype of a new model engine for Ripmax, the UKs
largest wholesale distributor of radio control models. The
unique engine, which is being tested by Ripmax, will be used in
control line speed model aeroplanes which will be flown in the
World Championships in 2010.
Micro Metalsmiths has been
working with Ripmax and
previously Irvine Engines for
over 30 years, providing intricate
prototypes and production castings
for model aircraft engines. The
partnership has proven to be
extremely successful, with control
line model aeroplanes developed
by Peter Halman going on to win
individual World and European
Championships, 14 World and
European team championships,
plus many UK championships in
the FAI F2A class.
Once completed the engine will
produce 2.5 horsepower at 40,000
rpm, which is the equivalent to
1,000 brake horse power (BHP)
per litre. The model aeroplanes will
reach 300 km/h.
Peter Halman, technical director,

at Ripmax said: Weve been

working with Micro Metalsmiths
for a number of years and their
personalised service has helped
us to develop leading edge model
engines for many of our radio
controlled aeroplanes. Being able
to work with rapid prototypes
will certainly have given us a
competitive edge, as it will have
allowed us not only to advance the
development of our engines, but
saved us valuable time and money
as well.
Christopher Shaw, chairman
and managing director of Micro
Metalsmiths added: We project
managed and developed nine
hot wax prototypes for Ripmax.
A benefit of using this particular
process is that it gives customers
the flexibility of only having a small

number of items developed at any one time. Another

is that the end result can often be more refined and
delicate, which is ideal for working on intricate solutions
like engine parts.
Micro Metalsmiths is an investment casting foundry
that can also provide microwave design, drafting,
machining and assembly skills, the result is a microwave
design and manufacturing facility ready to supply
standard and customised solutions for the challenges of
the RF & microwave electronics industry.
www.micrometalsmiths.com

Control
Line model
aeroplane
developed
by Peter
Halman of
Ripmax

Prototyping the good times

A difficult trading period in the first half
of 2009 was eclipsed by a brighter, more
positive period which saw Midas Patterns
finish the year strongly with production
moulding orders and new tooling orders
leading to a growth in workforce, says
managing director Alan Rance.
Located in Bedfordshire, England, the company
specialises in the manufacture of ultra high quality
polyurethane RIM mouldings. The company has
low cost, high quality tooling systems for producing
prototype (FASTrim) and production (MRIM)
volumes.
Working directly from 3D CAD data the companys
CAE department will design a FASTrim mould
tool within just a few hours. Utilising CAD/CAM
and multiple CNC machining centres a soft mould
tool is machined again within just a few hours.
Traditional patternmakers hand- finish the tools to
give an exceptional standard of finish and a feel of
real FASTrim quality. Tooling is then passed to the
moulding plant for rapid processing.
FASTrim tools are used in the production moulding
facility which guarantees Midas uses exactly the same
materials as in the companys production moulding
process, this means that FASTrim parts are ready
for testing, validation, design sign off and of course for sale.
1 off to 30 off parts
10-15 days to parts
Low cost tooling system
FASTrim tooling easily modified
Competitive alternative to SLA/SLS/silicon and
vacuum casting

FTJ May 2010

UL94/VO flame retardant parts

Production quality paint finishes
Full product assembly if required
Can cover prototype requirements through bridge tooling to specialist
production requirements

Aerospace - magnesium turbine housing casting

A complex set of pattern equipment that was manufactured in an unorthodox
way when the company was asked to help design a magnesium turbine
housing casting. Midas had to fully CAD model the casting detail (a 3mm
GWT magnesium turbine housing) using only old 2D paper based data
before regular pattern tooling design could start.
Once they had the casting model within CAD they had to machine a set of
prototype pattern equipment in Ureol to prove the design and functionality of
the running and gating system.
Once the running system had been perfected the companys in-house
traditional patternmakers then 'plasticated' the whole of the cast detail in
Ciba's 219 epoxy system (slate powder filled) to give a very hardwearing
stable and accurate pattern set.
The whole of this process, including the validation of the casting methods,
was carried out within 10 weeks.
Particular details to note are:
Good design ensures all cores locate easily and accurately
Very complex core build up demands zero tolerance stacking of cores
3mm general wall thickness demands high precision patternmaking
Very high quality resin patternmaking is illustrated
Good blend of CAE and traditional skills needed to achieve successful
result
High standard of craftsmanship shown on construction of frames,
handles, boxes etc.
Tight project management required to achieve tight deadlines
Midas Pattern Company Ltd, 22 Shuttleworth Road, Bedford, Bedfordshire
MK41 0RX United Kingdom.Tel + 44 (0) 1234 358394,
email:: sales@midas-pattern.co.uk
web: www.midas-pattern.co.uk

117

Rapid protyping

Rapid tooling applications

In today's competitive marketplace speed isn't everything
- it's the only thing, says Avi Cohen of Objet Geometries
Ltd. Here he looks at how rapid tooling (RT) can compress
time to market while reducing tooling costs. In addition, RT
techniques provide the ability to create parts from actual
end-use production materials and run quantities up to
production volumes, meaning more parts per mould.
In fact, RT techniques bridge the gap between room temperature vulcanised
(RTV) silicone rubber moulds and machined aluminium tooling. With RT,
longer runs of functional prototypes and pre-production samples can be
created in a wider range of materials. Also manufacturing analyses and field
trials can be conducted with fully functional parts. This enables you to finalise
the selection of production materials and to verify the tool prior to final mould
making.
RT is becoming the new model for the industry. Today, it is used mainly
for prototype tooling for low volume production. Depending on the part design
and the choice of the materials being injected, numerous different parts can
be developed. Many companies use rapid prototype tooling services, which
create precise moulds faster and with high-speed milling capabilities.
RT is not about the process but about the fast results and the success
gained from employing a leading-edge technology. It is a combination of
tools, methods, processes and people aimed at designing a rapid solution.
The term rapid tooling is used to describe a process which either uses a
rapid prototyping (RP) technique as a medium to quickly create a mould or
uses the rapid prototyping process to directly fabricate a tool for a limited
volume of prototypes. RT takes less tooling time and costs less than
conventional tooling. It can be used to make multiple parts out of alternative
materials. A shorter lead time is the primary advantage of RT. Process
modeling, rapid product development, rapid soft tooling, rapid bridge tooling,
rapid production tooling and the express tool process are all part of RT
technique list or processes related to making multiple parts out of alternative
materials with shortened lead times.
This article provides an evaluation of how Objet PolyJet Technology
fits within the RT arena and framework. We expect the PolyJet technology,
specifically the introduction of the process technology, to revolutionise
RT production and to bring with it additional benefits, including labourcost savings, a shortening of product development time and new design
development possibilities.
Objet's family of 3-dimensional printing systems brings high-resolution
RP solutions to RT environments. Objet's patented PolyJet Technologybased printing systems, which work with the companys FullCure materials
and software, provide a complete 3D printing solution for virtually any RT
application.
The strong interest in RT stems from a more broad directional change in
industry towards rapid product development. There are numerous reasons
for wanting to develop products quickly and there is a great deal of pressure
to do so. An example of an industry in which RT cycle time pressures are
well known is the automotive industry; the time needed to develop a new car
has been reduced dramatically in recent years. The shorter the development
time, the more effectively the developer can respond to current or recent
customer trends. However, it is not enough to develop a product rapidly.
The products need to be attractive in terms of the market drivers and the
manufacturing processes need to be both dependable and cost-effective.
Many engineers realise how vital it is to move new products to market
quickly. A company able to launch a product ahead of the competitors can
fully realise the market before rival products arrive and also tends to maintain
a dominant position for a few years even after competing products have been
released.

one-fifth that of conventional tooling; (2) tooling cost is

much less - the cost can be less than 5%; (3) tool life
is considerably shorter; (4) tolerances are wider.
RT holds value for many different industries. For
example, for the foundry industry, RT offers a fast,
cost-effective alternative for producing multiple
investment casting wax masters.
There is a wide variety of RT technologies
available, including prototype and bridge tooling and
short run as production tooling.
RT technology originally meant moulds could be
made much faster than with conventional machining.
That is still true. But in recent years, RT technology
has evolved towards building moulds that provide up
to 40% faster cycles than is possible with conventional
technology using proper mould design. This emphasis
on productivity accompanies a shift in RT applications
from prototype to full production tooling.
Newer RT approaches can minimise or eliminate
warpage and internal stresses caused by uneven
cooling. At the same time they can boost productivity
by drawing heat more quickly from thick sections
or other hard to cool features in the mould such as
bosses or ribs. Tests of newer, high-conductivity tools
by at least two sources reportedly found that cooling
time in the moulding cycle could be set to zero and the
process would still yield acceptable parts.
The spectrum of RT technologies encompasses
a few distinct approaches to producing a mould or
insert. Some create an insert with a surface layer of
tool steel and a core of conductive metal.
Common to all RT approaches is the creation of
mould-cooling channels which conform to the contours
of the part surface. This conformal cooling makes it
possible to draw heat out from areas that would be

Rapid tooling advantages

Rapid tooling is distinguished from conventional tooling in four key ways:
(1) tooling time is much shorter, as time to first articles is typically less than

118

Fig. 1 Typical tooling process

FTJ May 2010

Rapid protyping
hard to access with conventional cooling channels.
Conformal cooling could lead to a reduction in the
overall number of cooling lines needed, which would
save in tool build time.
For RT moulds to be successful, moulders need
to know how to use them properly. One has to be
careful not to cool the tool too quickly or you may not
get proper filling. Moulders using enhanced cooling
methods might have to adjust their moulding process
by increasing injection pressures and rates to ensure
the material reaches the end of fill in the tool. They
might also have to increase the temperature of the
printed model. Optimising the moulding process for
such a tool may entail changing the injection speed,
ejection speed, mould-opening and closing speeds,
mould temperature and cooling time.
A lack of understanding about how mould cooling
works can lead moulders to produce a lot of bad parts
fast. This is because with more of the mould surface
close to the cooling channel, thinner sections cool too
fast and then warp. A better approach is to move the
cooling channel closer to the cavity where there is a
hot spot and back it off a reasonable distance.
There may also be limitations on the minimum
size of features that can be produced. Unsupported
standing features need to have a minimum thickness.
If possible, runners and gates should be machined in
after the initial part build.

Fig. 2 Printed PolyJet mould for wax injection

Summary
The advantages of RT are lowered tooling costs as
compared to machining, and the possible use of
moulds of patterns made from RP. The drawback of
RT is that one can inject only basic part shapes and
that the parts might require secondary work. Viewed
in this light, RT offers the simplest medium for the
production of non-ferrous parts and for the production
of final parts with low tooling costs.
Taken as a whole, the RT process is often far
less expensive than other techniques and it is one
of the fastest methods available. It does suffer from
some disadvantages as it produces a product that
is limited in quantities per printed mould. However,
the advantages of RT outweigh its drawbacks. It
can achieve a wide range of shapes with a brief
turnaround, especially when based on previously used

Industry events
11-14 May 2010
Metal & Metallurgy China 2010
New China International Exhibition Centre, Beijing, China
Tel: +86 10 84600348, Fax: + 86 10 84600760,
www.ciec-expo.com
16-18 May 2010
IMA 67th Annual World Magnesium Conference
Kowloon Shangri-La Hotel, Hong Kong
Fax: +1 847 526 3993 Email:info@intlmag.org
Website: www.imaworldconference.org
16-19 May 2010
27th EICF International Conference
Krakow, Poland
Email: d.ford@eicf.org Website: www.eicf.org/events.php

Fig. 3 Printed mould for silicon injection

moulds or standard designs.

Objet's family of 3D printing systems brings high-speed rapid prototyping
(RP) solutions to the RT environments described here. Its patented PolyJet
technology-based printing systems provide a complete 3D modeling solution
for virtually any Rapid Tooling application.
2008 Objet Geometries, Ltd. All rights reserved. Objet Geometries, PolyJet, and
Eden are trademarks of Objet Geometries Ltd. and may be registered in certain
jurisdictions.

24-27 May 2010

Metallurgy - Litmash 2010
Expocentr Fairground, Moscow, Russia
Tel: +49(0)211-7793, Contact: Daniel Ryfishch, Email:
RyfishchD@messe-duesseldorf.de
Website: www.metallurgy-tube-russia.com, www.wire-russia.com
07-11 June 2010
MACH 2010
NEC, Birmingham, UK
Website: www.mach2010.com
23-26 June 2010
The 11th China (Guangzhou) Exhibition of Die Casting,
Foundry and Industrial Furnace
China Import & Export Fair Pazhou Complex, China
Tel: 86 20 38621295, Fax: 86 20 38620790,
Email: MeiWen@julang.com.cn, Website: www.julang.com.cn

For a full listing of future industry events please go to: www.foundrytradejournal.com

FTJ May 2010

119

Rapid protyping

The world of rapid prototyping under one roof

Originally established in 1946 to restore the foundry
industry in Poland, the countrys Foundry Research
Institute has now become an advanced centre for research
and development housing state-of-the-art equipment, highly
trained personnel and practical research objectives - it is
quite simply a world leading facility.
As part of the wider Institute, around 6 million zloty was invested in the
Institutes Centre for Designing and Rapid Prototyping which has a wide
range of equipment and the latest technology including 3D printing, FDM
(fusion deposition modelling), LOM (laminated object manufacturing) and
SODjet. The scope of work undertaken in the centre includes: making
prototype castings and tooling by RP techniques; development of technology
for near-net-shape castings using new generation liquid ceramic slurries;
evaporative pattern process casting; application of numerical computations in
casting design optimising and technology verification.
In addition to the above casting technology work, the centre is also
committed to studies and research on developments in moulding and
auxiliary materials to determine the best properties of said materials for the
manufacture of foundry patterns and pattern tooling used in RP systems.
Technology designing and verification is an important part of the Centres
research and, with the help of Abaqus software, staff are involved in
the analysis of static and dynamic stresses, heat flow, acoustic effects,
piezoelectricity and shock waves in liquids. Using Solid Edge software
the design and development of casting manufacturing technologies using
3D patterns is investigated and simulation is studied with the help of
MAGMAsoft.
A number of patternmaking techniques are under the watchful eye
of personnel involved in various projects with functional patterns for
prototypes made from powders and binders. Using Spectrum 510, 310 plus,
architectural and artistic visualisations are available using a rapid and highly
efficient 3D printing system with a complete 24-bite colour palette in 600 x
540 dpi resolution with a working chamber dimension of 254 x 356 x 203mm.
Reverse engineering is possible thanks to scanning in 3D digitalisation of
both technical and decorative models, which is done using a ROMER Sigma

120

S; ATOS III - the computer then reconstructs historic

monuments or artworks. The centre is using this
technology to build a virtual museum - a database
of artistic items for cataloguing purposes - for future
generations so, as the Institutes general manager
Prof Dr Jerzy J Sobczak says: artwork such as
sculptures will never be lost as we have a record on
file.
Foundry patterns for the lost wax process are
produced using a T612 Solidscape Benchtop 3D wax
printer. With excellent accuracy and high precision
there is a working chamber of 300 x 150 x 150mm and
an applied layer thickness of 0.013 - 0.076mm. The
high precision in the reproduction of all details makes
this an ideal choice for small and highly accurate wax
patterns (e.g. for jewellery).
A vacuum chamber is used for wax patterns,
patterns from synthetic resins, silicone moulds and
moulds and core boxes made in synthetic resins.
The art of making metal vacuum castings - poured
in plaster moulds under vacuum - is undertaken for
aluminium castings up to 7kg. Induction furnaces are

Advanced Prototyping
Techniques
CAD designing (Solid Edge)
Technology verification (MAGMAsoft, ABAQUS)
Patternmaking (patterns made in plastics,
composite, powders, wax, resin)
Prototype castings
3D scanning (digitalisation)
Particle size measurements in micro and nano
scale
Ceramic mould making

FTJ May 2010

Rapid protyping
Main photo opposite: Members of the WFO executive
committee view some of the equipment and facilities at the
Foundry Research Institute in Poland they are seen here
with Dr Natalia Sobczak (far right) of the FRI and also
the chairman of the WFO cast composites commission

used for aluminium and iron castings up to 10kg.

The centre also has apparatus for examination
of physical and chemical properties of moulding
materials such as particle size analysis for 0.6nm6m.
All research is based on practical foundry needs
with the focus on improving productivity and quality
of castings. Physio-chemical and technological
properties are under the spotlight with the need to
further enhance capabilities to improve near-netshape casting technologies for the wider benefit of the
industry.
Rapid prototyping and design is just one aspect
of a much wider organisation which is active in
research and development at a number of levels for
all materials, casting processes, high temperature
studies, designing, simulation, forecasting, trends and
information dissemination.
Such are the capabiities of the Institute, based
in Krakow, that the Ministry of Science and Higher
Education is the main sponsor having recognised the
worldwide importance of the work undertaken at the
facility and its strategic position in the global foundry
industry.
Of the 94 staff employed 80% are R&D and
scientific workers tasked with a number of general
foundry development and task-specific projects. Along
with the RP Centre there are departments for ferrous
alloys, non-ferrous alloys, and technology; centres
for high temperature studies of metals and alloys,
information and promotion; and an office for product
certification and standardisation. A significant amount
of the Institute is dedicated to research laboratories
for materials science and measurement methods,
environmental studies, chemistry and moulding
materials, structure analysis and mechanical testing,
and applied research looking at fracture mechanics,

Prof Jerzy J Sobczak, Foundry Research Institute (left) with WFO President Don
Huizenga (centre) and Prof Jozef Suchy of AGH University Poland

residual stresses and shape resistance of structural elements. The

Laboratory of Applied Research works on projects directly for the industry
with tests and examinations based on acoustic emissions.
Packed with high tech equipment, the Institute has the latest highly
powerful scanning probe microscope and one of only a handful of Phoenix
x-ray nanotom machines in the world. The x-ray computed tomography is
being used for checking the properties and quality of a titanium casting used
for an artificial heart project which the Institute is a development partner for.
Dr Sobczak says the Foundry Research Institute has to effectively face the
needs of foundry science and practice at a national and international level.
He recently invited the World Foundry Organization executive committee to
tour the facility and give their opinions on whether this objective was being
met. WFO president Don Huizenga said: This is one of the best facilities
I have seen anywhere in the world. The balance of high-end research and
practical foundry needs is commendable and the level of financial investment
matched with genuine industry-led projects with tangible benefits is proof of
its worth.
For more information contact: Prof Jerzy J Sobczak, Foundry Research
Institute, Zakopianska 73, 30-418 Krakow, Poland.
Tel: +48 (12) 261 83 24, email: sobczak@iod.krakow.pl
web: www.iod.krakow.pl

Rolls-Royce factory of the future venue for RP event

A seminar on rapid prototyping will be held at the Rolls-Royce factory of the future in Rotherham on Wednesday 12 May 2010.
In conjunction with the Advanced Manufacturing Research Centre with Boeing, the full-day event will explain and demonstrate the
applications, opportunities and benefits of using selective laser sintering (SLS) and direct metal laser sintering (DMLS) throughout all
stages of the product life cycle. The event is the latest in a series organised by 3T RPD Ltd.
The use of rapid prototyping technologies by engineers, architects and designers is rapidly becoming the norm rather than the
exception, revolutionising the speed at which products can be brought to market.Coupled with new opportunities for low volume
production, rapid manufacturing is becoming a reality for many industry sectors.So its essential to have sufficient knowledge to make
the most of what these technologies have to offer.
The seminar will demonstrate how SLS and DMLS technologies enable the cost-effective, fast and accurate production of durable
and complex components, whilst negating the investment in conventional tooling.3Ts technical experts will be available to give
advice on specific projects or help with any data issues or questions, and topics covered will include:
Understanding SLS and DMLS to get the most out of them
The benefits you can achieve from the technologies
Applications that SLS and DMLS are good for, and those that theyre not!
Constraints and opportunities
Materials and applications
Designing for the SLS and DMLS processes
Making sure your CAD data is of good quality
Production opportunities
The registration fee is 45/delegate Registration, and bookings can be made online by visiting the seminars section at www.3trpd.
co.uk, by emailing sue@3trpd.co.uk or contacting Sue Burnip on Tel: +44 (0) 1635 580284. Members of the Advanced Manufacturing
Forum (AMF) can attend free of charge.

FTJ May 2010

121

Rapid protyping

Impossible to make? Not any longer

Newby RapidCast is a division of the
Newby Foundries group specialising in
providing cost effective rapid prototyping
solutions, here we look at some examples
of products produced using the latest RP
techniques.
Rapid prototyping is increasingly used in product
development due to its ability to significantly lower
development costs, reduce time to market, and provide
accurate feedback on performance.
By utilising the facilities within the group and selected
outside suppliers, Newby gives customers access
to the widest possible range of the latest processes
and techniques from a single source, and provides a
seamless integration from the design and prototype
stage through initial production samples and on to
volume production. Castings can be produced directly
from a 3D CAD file in as little as three to four days,
without the need to produce a pattern of any kind.
The Newby Foundries group was established over a
century ago, and has developed a wealth of experience
in the production of castings. The companys CAD
engineers can call on this experience to assist in the
design and development of products from the initial
concept stage through to volume production.

set, and Shell moulding techniques

were all used to produce the range
of parts in the minimum timescale
at the lowest possible cost. The
various parts were supplied fully
machined to the customer, thereby
providing a turnkey solution (fig.3).

3D sand printing

A market leading tap manufacturer contacted Newby

Rapidcast to help in developing a revolutionary
tap based around designs from an internationally
acclaimed architect (fig.1). Newby helped develop new
manufacturing processes that enabled the successful
casting of this functional piece of art. By utilising
patternless sand printing, wax printing, metal flow
simulation and CNC pattern equipment, the tap has
been taken from concept to production and a casting
has been produced which was thought to be impossible
to make (fig.2).
A leading UK automotive manufacturer needed a
range of castings to produce a series of heavy duty
prototype transmissions. The requirements were for 220
castings from 12 different designs with a timescale of six
weeks from concept to delivery of the castings.
The volume requirements for the various parts were
such that no one process was suitable to produce all
the castings. The patternless sand printing process, Air

The company uses an advanced

3D printing process which allows
for the creation of sand moulds and
cores direct from CAD data without
the need for tooling. This process
has massive benefits for the
production of small batch castings
in terms of cost and timescales.
A wide range of materials and
geometries that are impossible to
produce using traditional methods
can be cast.The maximum build
area of this machine is 1500 x 750
x 700mm and the method allows
castings to be produced in as little
as three days from receipt of the
final CAD data.
By combining 3D sand printing
and shell/airset moulding a fast,
cost effective method of producing
castings is achievable which
allows for small batch production
and quicker time to market for
full production batches. Typical
applications include the production
of complex core assemblies
without the need for tooling, and
production castings to be produced
while waiting for full core mould
patterns. Custom hybrid prototype
techniques can also be developed
where unique casting geometries
are required.
The production of concept
models is also offered by the
company with a maximum build
size of 250 x 200 x 200mm,
although larger components can be

Fig. 1

Fig. 3

Tapping into RP

122

Fig. 2

assembled. This technique offers

customers:
Fit and form validation
Physical concept models
Functional testing
Flow analysis
3D FEA analysis
Prototype mould production
Finished components

What are the benefits of rapid

prototyping?
Short development cycles
Physical models can be
produced in a few days, reducing
time to market.
Low development costs
Prototypes can be produced
before any commitment to costly
tooling.
Accurate feedback
Communicate your design
intentions to your clients,
toolmakers, and other
departments easily and
effectively and ensure the
finished product is fully
developed.
Newby Foundries Ltd, Smith Road,
Wednesbury, West Midlands,
WS10 0PB United Kingdom.
Tel: +44 (0)121 556 4451. email:
design@newbyfoundries.co.uk
web: www.newbyrapidcast.co.uk

FTJ May 2010