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The Half-Million-Dollar Gasket Problem The customer had a problem sitting on the conference table. A gigantic gasket interface.Big sealing surface.Expensive assembly.High consequence
“Somebody’s Going to Get Hurt” The foundry manager pointed at the old match plate. “See that?” I looked at it. Aluminum plate.
From 750 Pounds to 16 Pounds: A Better Way to Build Foundry Tooling Some foundry problems are obvious the moment you see
From Part to Pattern: Creating Digital Foundry Tooling from an Existing Part Sometimes the pattern is gone. Sometimes the drawing is outdated.Sometimes
Your Foundry Pattern Needs a Digital Twin A foundry pattern sitting on a shelf is not the same thing as a backup
A mid-sized foundry had a pattern room full of legacy wood patterns. Some were active jobs. Some were old customer tooling. Some
Bondo Is Not a Production Strategy If your foundry is repairing the same pattern with Bondo between pulls, that pattern is not
Stop Patching Worn Foundry Patterns Between Pulls Every foundry has seen it. A pattern is old. The edges are soft. The fillets
Six Foundry Lessons Learned: Where 3D Printing Could Have Saved Time, Money, and Rework 1. The Match Plate Built Too Soon A
Prototype Casting Patterns: How to Validate a Design Before Production Tooling Production tooling is expensive. Before committing to machined tooling, match plates,
How Foundries Can Reduce Pattern Storage Problems With Digital Tooling Pattern storage is a real problem for many foundries. Physical patterns take
When to Use a Loose Pattern Instead of a Match Plate Not every casting job needs a match plate. For some projects,
31st
31st
May, 2026
Using Development Boards in Early Hardware Prototypes Other Parts of this series: Part 2 – Choosing The Right Development Board Part 3
29th
29th
May, 2026
Why Bigger 3D Printed Parts Don’t Always Need High Resolution Many customers assume the finest layer height produces the best 3D printed
29th
29th
May, 2026
Why Supports Can Double the Cost of a 3D Printed Part One of the most common misunderstandings in 3D printing is the
25th
25th
May, 2026
Memorial Day Traditions: A Simple 3D Printed Flag Holder for Graveside Flags Memorial Day is a time of remembrance. Across the United