Patterns & Tooling

Specifications

Applications for Industrial Patterns & Tooling

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LMP manufactured pattern tooling is used by greensand, no bake or hardsand foundries, shell foundries as well as a variety of other sand casting foundries. Patterns are produced for thin walled parts- sought after by brass, bronze and aluminum foundries- to heavy section castings for iron and steel foundries.

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Factors Effecting Pattern Construction

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Material selection and features created in the pattern are dependent on the quantity of parts to be molded off of the pattern, the shape of the tool or the construction necessary to hold up to the process, the type of molding process being used (hand/machine molding) and the customer budget.

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Molding Processes using Industrial Foundry Patterns & Tooling
   
Sand foundries and refractory companies use industrial patterns and tools to manufacture final parts. A wide variety of molding methods and processes are used in conjunction with industrial foundry patterns and tools including:

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• Hand Molding

  • No-bake/Pep-set Molding

• Machine Molding

  • BMP/BMM Molding

  • Disamatic Molding

• Floor Molding

  • Sand Foundry/Green Sand/Soft Sand Molding Process

• Squeeze Molding

• Impact Molding

• Blow Sand Casting

• Shell Process

Pattern features depend on the type of process used and the type of mounting that process requires for the pattern.

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Industrial Pattern Features
   
LMP will bench machine or CNC machine your patterns and core boxes and provide them to you loose or mounted on wood boards or metal plates. We can provide process-specific locators, pins, bushings and guide plates for your foundry ready tooling.

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We will prepare your tooling to run in your tight flask, snap flask or mold box process, producing cheek patterns or upsets as required.

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Features specific to the application can be added into the pattern or tool. These features can include (if applicable):

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• Gating

• Risers

• Tight tolerance, intricate patterns

• Labeling/Logos/Engravings

• Cast thread detail

• Zero-draft cores

• Cooling fins

• Prep / pin / bolt locations (for large patterns/tools)

• Pouring basins

• Hot / Cold Core Boxes

• Mold Boxes

• Cheek Patterns

• Flask Upsets

Compatible Equipment
   
The industrial patterns and tools we make can be used on a variety of machines and we can make patterns specific to the machines our clients have at their foundries. We have made patterns compatible with:

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• Beardsley & Piper (BLP) Machines

• British Molding Machines (BMM)

• Disamatic Molding Machines

• Hunter Molding Machines

• Sinto Molding Machines

• Gaylord Molding Machines (for core molding)

Industrial Pattern Materials
   
LMP can manufacture industrial foundry patterns from materials such as:

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• Wood

  • Mahogony

  • Pine

  • Maple

  • Gelutong

  • Poplar

  • Ash

  • Oak

• Metal

  • Aluminum

  • Iron

  • Steel

• Plastics

  • 2 Part Epoxy Resins

  • Urethanes

• Foam Tooling Boards

  • Polystyrene- 1-3 lb. density

  • Polyurethane- 25 lb. density

• Foundry Tooling Boards

  • RenShape Foam Boards and Styping Boards

Production Methods
   
LMP's craftsmen bench pattern makers work to shape most patterns from various types of wood. This industrial woodworking involves using hand tools, manual machines and CNC machines to create the final pattern.

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When fabricating foundry tooling and patterns out of other materials such as metals and plastics- manual and CNC machining is utilized along with water jet cutting, Electric Discharge Machining (EDM) and laser jet cutting to create the correct features and dimensions of the pattern.

Secondary Operations
   
On top of providing industrial patterns and tools to foundries, LMP can provide:

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• Revision Modifications

• Inspection Services

• Maintenance Services

• Spare Parts / Multiple Loose Pieces

• Pig Molds

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Besides manual and CNC machining, LMP can perform secondary operations to achieve tighter tolerances, different finish characteristics or geometries that would not be possible with traditional machining methods. These operations include:

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• Wire EDM

• Water Jet Cutting

• Sand Blasting

• Hand Benching

• Coating Applications- Pattern lacquer is applied to provide a smooth, air-tight surface as well as a color-coating for easy identification.

Part Size Limitations
   
We can manufacture patterns and tooling of all sizes- from small, intricate equipment to large equipment with several sections requiring multiple shipments for on-site assembly.

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LMP has created patterns for products as small as Thumb Screws (1/4" x 1/2") up to parts 20 ft x 20 ft x 45 ft.

Machining Tolerances
   
LMP has the ability to produce your smallest most intricate parts, molds, and models with tolerances +/- .005” using conventional and CNC machine tools.

Quality Control Practices
   
LMP provides basic manual inspection of every part. We can also provide CMM (coordinate measuring machine) inspection as well as an optical scan of the finished pattern. Optical scanning allows LMP to provide exact 3D geometry which can be overlaid onto the original 3D CAD model of the pattern. A comprehensive report and visual record of the variations of the final pattern from the original drawing can be provided to our clients.

Production Volume
   
LMP provides custom built to specification tooling- typically in a single quantity.

Preferred Drawing Submission
   
We support DWG, DXF, IGES, DSN, SCPRT, x_t and other customer files utilizing our Surfcam software and can arrange for file conversion of any program we do not currently support.

Software
   
LMP uses Surfcam CAD/CAM Software for all tooling design and fabrication.

In-House Equipment
   
Motionmaster 60 x 60 x 30 CNC 5-axis router (2)
Thermwood 60 x 120 3-axis CNC
Freyer 30 X 60 X 30 3-axis Vertical Machining Center
Cintimatic 18 X 30 X 18 3-axis Vertical Machining Center
Wadkins Vertical Turning Center

Industries Served
   
Foundry
Refractory