Post on 06-Jul-2015
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FOPAT Production Inc.
Investment Casting Patterns
FOPAT Production Inc., www.FOPAT.com, September 2009
History:• The FOPAT project began in the 1990’s
• Designed as the next generation investment casting pattern material to replace or be used as an alternative to the lost-wax process
• FOPAT Production Inc. (FPI) was launched in October 2008 to commercialize the FOPAT technology
• Sponsored through Government Programs• DOE I&I (Inventions & Innovations)• DoD SBIR (Phase I & Phase II)
• New 14,000 sq ft facility located in Miamisburg, OH
2FOPAT Production Inc., www.FOPAT.com, September 2009
What is it?• A FOam PATtern material
• Made from multi-component foam
• Proprietary formulations
• An injectable foam
• An investment casting pattern
FOPAT Production Inc., www.FOPAT.com, September 2009
Technology Overview:
FOPAT Production –
• Reaction Injection Molding (RIM)• Two Reactive Components• Mold Injection
• Proprietary Process and Formulation
• Low Density, High Quality Surface Finished Patterns
• Increased Dimensional Accuracy & Temperature Stability
4FOPAT Production Inc., www.FOPAT.com, September 2009
Investment Casting Needs
Present Wax Process FOPAT Technology Advantage
Increased dimensional
accuracy
Unstable waxes due to melting and solidification,
shrinkage adjustment needed.
~0% pattern shrinkage gives stable pattern
(material expands into die)
Increased temperature
stability
Needs temperature controlled dies and rooms.
Wax expands when minimally heated
Can withstand temperatures up to
~200 degrees F. without distortion
Less energy consumption per
pattern
2 melting cycles and one holding of wax to
approx.150 degrees F
No heating required, room temperature
process
Improved Performance Beyond Wax
5FOPAT Production Inc., www.FOPAT.com, September 2009
Investment Casting Needs
Present Wax Process FOPAT Technology Advantage
Decreased tooling Decreased tooling costcost
CNC cut aluminum tooling CNC cut aluminum tooling required to cool patternrequired to cool pattern
Low cost plastic or Low cost plastic or composite tooling is composite tooling is
possiblepossible
Increased casting Increased casting yieldyield
Wax dimensions change Wax dimensions change and wax can cause shell and wax can cause shell
cracking defectscracking defects
Stable pattern Stable pattern dimensions and dimensions and
minimal or no shell minimal or no shell cracking defectscracking defects
Lighter Patterns to Lighter Patterns to improve improve
manufacturability manufacturability of shells of shells
Density is ~64 lbs/cu ftDensity is ~64 lbs/cu ft Density as low as ~4-5 Density as low as ~4-5 lbs/cu ft lbs/cu ft
Improved Performance Beyond Wax
6FOPAT Production Inc., www.FOPAT.com, September 2009
Investment Casting Needs
Present Wax Process FOPAT Technology Advantage
Longer, thinner Longer, thinner sectionssections
Limited in length due to Limited in length due to creepcreep
No creep – long, thin No creep – long, thin sectionssections
Pattern handlingPattern handling Fingerprints, fragile, temp Fingerprints, fragile, temp sensitivesensitive
Stiff, light, easy to Stiff, light, easy to handlehandle
Pattern ShippingPattern Shipping Temperature controlled Temperature controlled trucks and special trucks and special packaging fixturespackaging fixtures
Easy to ship – Easy to ship – significantly lower significantly lower
cost to shipcost to ship
Improved Performance Beyond Wax
7FOPAT Production Inc., www.FOPAT.com, September 2009
Production Progress UpdateNew Custom Machine:
• Increased Production
• Multi Shots in Seconds
• Variable Shot Settings
• Quality Controls
• Temperature
• Shot Size
• Historic Data
• Less Scrap
8FOPAT Production Inc., www.FOPAT.com, September 2009
Production Progress Update
New 10 Foot Arc Table
• Water Lines - heat
• Air vent built in
• Additional arc can be added
• Chases being added• Speed / balance - less fatigue
Old rectangle tableOld rectangle table
New 10” Arc TableNew 10” Arc Table
9FOPAT Production Inc., www.FOPAT.com, September 2009
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Breakthrough Technology for Casting Patterns
FOPAT Production Inc., www.FOPAT.com, September 2009
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Benefits of FOPAT Technology
• Potential for low cost tooling materials
• 0% pattern shrinkage produces stable pattern
• Stable pattern dimensions yield no shell cracking defects
• Capability to withstand temperatures up to 200 degrees F.
• Potential for 30% material cost reduction for a given pattern
• Relatively low temperature process, saving energy
• Usable at any foundry with current casting techniques
• Patterns can be easily shipped without damage or distortion
FOPAT Production Inc., www.FOPAT.com, September 2009
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Economic AnalysisPrice each
Price each
Price each
Price each
Price each
1 pc 5 pcs 10 pcs 20 pcs 50 pcs
RP pattern $1,085 $462 $386 $386 $386
FOPAT Pattern $1675 $375 $212 $131 $82
SLA Mold $1,623 $1,623 $1,623 $1,623 $1,623
FOPAT Pattern (includes Mold costs) $2615 $563 $306 $178 $101
FOPAT silicon Mold (includes master) $2,565 $2,565 $2,565 $2,565 $2,565
FOPAT Production Inc., www.FOPAT.com, September 2009
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Economic AnalysisPrice each
Price each
Price each
Price each
Price each
1 pc 5 pcs 10 pcs 20 pcs 50 pcs
RP pattern $750 $298 $298 $298 $298
FOPAT Pattern $1640 $367 $208 $129 $82
SLA Mold $1,587 $1,587 $1,587 $1,587 $1,587
FOPAT Pattern (includes Mold costs) $2070 $454 $252 $151 $90
FOPAT silicon Mold (includes master) $2,020 $2,020 $2,020 $2,020 $2,020
FOPAT Production Inc., www.FOPAT.com, September 2009
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Key DifferencesKey Steps in Traditional Lost Wax Investment Casting
Machining ofAluminum
Tooling
WaxFormulation
& Melting(2 melt cycles)
Wax Holding ator Above MeltTemperature
Build Shell,Melt & Pour
Metal
Key Steps in Proposed FOPAT Investment Casting
BuildInexpensive
Plastic Tooling
Formulate & Inject FOPAT(Exothermic
Process)
Build Shell,Melt & Pour
Metal
Greater Yield &Lower Material,
Process andEnergy Costs
FOPAT Production Inc., www.FOPAT.com, September 2009
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Impact on Energy, Material, & Productivity• $6 billion of investment castings produced in US annually, with $16B worldwide
• 35 million pounds of wax are used annually in the investment casting process (formulated, injected, and heated)
• Energy required in wax melting process = 260,000,000,000 BTU used per year (US)
• 695,000,000, 000 BTU used per year (worldwide)
• Corresponding cost of energy = $1,724,210 per year (US) = $4,586,400 per year (worldwide)
FOPAT Production Inc., www.FOPAT.com, September 2009
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Energy Savings
FOPAT proposed pattern material eliminates energy-consuming steps by:
• Reducing pounds injected each year ; 4,400,000 = 0 BTU (Exothermic process actually produces heat)
• Cost of energy to heat material each year = $0 (No heat required)
• Corresponding cost of energy = $1,724,210 per year (US) = $4,586,400 per year (worldwide)
FOPAT Production Inc., www.FOPAT.com, September 2009
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Environmental BenefitsFOPAT proposed pattern material provides:
Less Waste to Landfills -
• Reduced Ceramic shell material•Since ~ 200,000,000 pounds of less metal that needs to be poured when FOPAT process is used, there would be ~ 50,000,000 pounds of ceramic not going into landfills.
• Reduction of CO2 emissions• Foundries would reduce the melting emissions by 0.2 pounds of CO2 per pound of steel not melted or ~ 40,000,000 pounds of CO2 per year
• Less Energy for the reduced amount of melting• Electric utility producing less energy by about 60,000,000 kWh/year x 2.3 lbs CO2/kWh = 138,000,000 lbs CO2/year
FOPAT Production Inc., www.FOPAT.com, September 2009
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Total Economic Benefits
• Scrap Reduction Economic Savings = $224,000,000 per year
• Reduction in the Use of the Ceramic Shell = $15,000,000 per year
• Alternate Tooling Materials = $135,000,000 per year
• TOTAL POTENTIAL SAVINGS = $419,000,000 per year
FOPAT Production Inc., www.FOPAT.com, September 2009
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Why use FOPAT?
• Can be made from RP molds
• Very accurate and repeatable
• Dimensionally stable with thin wall applications
• Very Foundry friendly
• Cost effective in both short-run and multiplerun productions
• Competitive pattern cost compared to wax
FOPAT Production Inc., www.FOPAT.com, September 2009
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THANK YOU!Contact us or visit our website at: www.FOPAT.com
Tim Large, Technology Commercialization ManagerbuyCASTINGS.com/FOPAT Production Inc.2411 Crosspointe DriveMiamisburg, Ohio 45342tim.large@buycastings.com(937) 389-6827 or 1-866-289-2278
FOPAT Production Inc., www.FOPAT.com, September 2009