Crack Patternmaker 7

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This lecture was presented at the 3D Digital Documentation Summit held July 10-12, 2012 at the Presidio, San Francisco, CA The Patternmaker’s Art: Innovation within a Timeless Tradition With a few exceptions, architectural metal castings are made using hollow cavity sand and clay molds. The molds are made by compacting the sand around patterns which look like the casting being made. The molds are negatives and the patterns are positives. All foundrymen know the importance of a pattern, because the casting can never be better than the pattern being used to produce it. It is the beginning of the process. Patterns are the transformation of ideas into reality.

Consequently, the pattern shop is usually a popular place, staffed with highly skilled craftsmen who have intricate knowledge of materials and the machinery necessary for precision patternmaking. The Civil War created a period of substantial growth in the iron foundry industry. At the conclusion of the war, many of these foundries moved into architectural castings offering a wide variety of products for the home, garden and commercial buildings. This period, known as the golden era for Victorian cast iron architecture, and the resilience of cast iron itself, is the reason so many examples remain to this day. Many foundries used catalogs, or pattern books, to make sales. Patterns would often begin as sketches or renderings. These drawings would be carved in wood by hand to create master patterns.

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The master patterns were usually used only once to cast working patterns in iron. The working patterns were hand-tooled in the sand molds by skilled molders who, in many cases, poured their own molds with molten iron.

In later years, as labor rates increased, metal matchplates were developed to speed the molding process. In the 80’s the used of plastics for patternmaking became more predominant. The urethane based plastics were a lighter and less expensive option than metal matchplates. Multiple plastic impressions could be mounted to an inexpensive wood board for foundry use. The use of urethane plastics continues to this day. All patterns used for sand castings have a parting line. The parting line is the point at which the two halves of the sand mold are separated, allowing the removal of the pattern without tearing the mold walls.

The minimum angle for a parting line is three degrees. Since all molten metals shrink as they solidify, patterns must be larger than the casting being produced. For cast iron, the shrinkage rule is one-eigth inch per linear foot. Consequently, patternmakers must use special shrinkage rulers so that the castings will be dimensionally correct. In order for molten metal to flow evenly into the hollow cavity in the sand mold created by the pattern, a gating system must be designed and attached to the pattern board. The gating system is critical to casting quality. The most typical gating system consists of a long runner with in-gates feeding the casting.

The form used to create the sand mold is called a flask. One of the patternmaker’s functions is to co-ordinate the flask sizes with the foundry. This is important because the flask size relative to the pattern size determines the yield of the mold, which is a very large factor in the cost of the casting. Recent technological advances have moved the time honored craft of patternmaking into the digital age.

The use of three dimensional computer generated models to create patterns is now possible. One way to generate the model is through traditional AutoCad programming. AutoCad models are converted to “G” code using a program called MasterCam. This code is then loaded into a three dimensional router to be cut in solid material. The preferred material is urethane based Renshape tooling board. Another way to generate the model is through the use of laser scanners.

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The procedure involves the attachment of 2mm positioning targets to the object being scanned. Much like GPS, the scanner uses triangulation to keep its position in space during the scan process.

The scanner renders real time models viewable on the computer screen enabling the operator to monitor the scan quality. Once the scan is complete the acquisition software converts the surfaces into an STL file. This file is then imported into RapidForm, a powerful reverse engineering program, to turn the scan into a functional 3D model. The model can be adjusted for shrinkage after it is exported to MasterCam just prior to cutting in a 3D router.