2018 Additive Manufacturing for Metalcasting Conference

Louisville Marriott Downtown
Sept. 10-13, 2018


Additive Manufacturing for Metalcasting Conference is America’s premier conference on the use of 3D printing in the metalcasting industry. Come see how the metalcasting supply chain is using this new technology to secure new customers, improve existing components and enhance their profitability. The conference will cover all aspect of additive manufacturing and 3D printing in metalcasting and highlight many practical applications and case studies. Whether you are just thinking about additive manufacturing or already involved, this conference will provide practical help.

Among the topics being covered:

  • Casting design parameters for 3D printed cast components
  • 3D printed sand molds and cores
  • 3D printed hard tooling
  • Printed expendable patterns for investment casting
  • Equipment & maintenance
  • Materials; sand and binders for 3D printing
  • Case studies of castings produced through additive manufacturing
  • Emphasis on new and innovative technologies, case studies and the variety of processes available

The conference includes a tour of the University of Louisville Rapid Prototyping Center.


  • Louisville Marriott Downtown
  • Louisville, Kentucky
  • Sept. 10-13, 2018
Get Directions

Hotel Information

Louisville Marriot Downtown
  • Louisville Marriot Downtown
  • Louisville, KY
  • $169/night

Room Block Release Date: Sunday, August 19, 2018

Reservations must be received on or before 12:00 p.m. on Sunday, August 19. At the cutoff the hotel will review the reservation pickup and release any unreserved rooms for general sale. Room reservations made after the cutoff date will be made on a space- and rate-available basis at the AFS group rate after this date.


On-site parking, fee: 10 USD hourly, 27 USD daily

Valet parking, fee: 32 USD daily

Travel Information

Airport/Hotel Transportation

Louisville International Airport (SDF) http://www.flylouisville.com/

The Louisville Marriott Downtown does not provide shuttle service.

Estimated taxi fare: 18 USD (one way) / Hotel direction: 8 miles N

Alternate transportation: R&R Limousine (800-582-5576) or Xtreme Transportation (812-246-2235); fee: 75.25 USD (one way); reservation required

Rental Cars

Rental counters are located on the lower level near baggage claim. Transportation is provided outside on the lower level.

Driving Directions

From Louisville International: Take 264 East one mile to I-65 North. Travel about 6 miles to Brook Street exit. Turn left onto Jefferson. The hotel entrance is immediately to the left on Jefferson Street.


Conference Agenda

Monday, September 10, 2018
11 a.m. - 1 p.m.
1 - 4:30 p.m.
Tours of University of Louisville Rapid Prototyping Center and UL’s Additive Manufacturing Competency Center

Tim Gornet, Professor at University of Louisville, Louisville, KY

Tuesday, September 11, 2018
7 - 8 a.m.
8 - 8:15 a.m.
Welcome, Conference Chair

Brandon Lamoncha, Humtown Products, Columbia, OH

8:15 - 9 a.m.
KEYNOTE: Additive Manufacturing-The Path to Production

Ron Walling, Cummins, Columbus, IN

9 - 9:30 a.m.
Decision Process for Purchasing Your Own Machine

Dylan Kleitz, Bremen Castings Inc., Bremen, IN  

9:30 - 10 a.m.
Conventional Cores Converted to 3D Printed in Production

Brandon Lamoncha, Humtown Products, Columbia, OH

10 - 10:15 a.m.
10:15 - 10:45 a.m.
Using a 3D Sand Printer─Lessons Learned

Doug Trinowski, HA International, Westmont, IL

10:45 - 11:15 a.m.
State of AM Standards in Metalcasting Applications

Sheku Kamara, Milwaukee School of Engineering, Milwaukee, WI

11:15 - 11:45 a.m.
Designing for Printing vs Conventional - Case Studies

Aaron Kepler, Caterpillar Inc., Mapleton, IL

11:45 a.m. - 12:15 p.m.
3D Printed Smart Molds for Sand Casting

Eric MacDonald, Youngstown State University, Youngstown, OH

12:15 - 1 p.m.
1 - 1:15 p.m.
AFS Activities and Vision 3D Printing for Sand Casting

Jiten Shah, Product Development & Analysis, Naperville, IL

1:15 - 1:45 p.m.
Casting Design for Part Consolidation

Jiten Shah, Product Development & Analysis, Naperville, IL

1:45 - 2:15 p.m.
Phenolic and Large Format Printing for Volume Production

Aaron Howard, Voxeljet, Canton, MI

2:15 - 2:30 p.m.
2:30 - 3 p.m.
How Robotic 3D Printing Is Transforming Metalcasting

Howard Rhett, Viridis3D, Woburn, MA

3 - 3:30 p.m.
What's Needed for Next-Generation 3D Sand Printers

Rick Lucas, ExOne, Irwin, PA

3:30 - 3:45 p.m.
Case Study: Digital Patternmaking

Ted Kahaian, TEI, Livonia, MI

3:45 - 4 p.m.
Case Study: Printed Ceramic Media for Narrow Opening Products

Marshall Miller, Flowserve, Irving, TX

4 - 4:15 p.m.
Case Study: Sand vs. Investment Casting: Making the Decision

Jerry Thiel, University of Northern Iowa, Cedar Falls, IA

4:15 - 4:30 p.m.
Case Study: Printed Sand Molds for Impellers

S.Ethan Edwards, Trident Alloys Inc., Springfield, MA

4:30 p.m.
Case Study: Applying 3D Sand Printing and the Benefits You Can Achieve

Dave Rittmeyer, Hoosier Pattern, Decatur, IN

Wednesday, September 12, 2018
8 - 8:45 a.m.
AFS Activities and Vision: 3D Printed Tooling

Marshall Miller, Flowserve, Irving, TX

8:45 - 9:15 a.m.
The State of the Art in Plastic 3D Printing for Pattern Manufacturing

Clay Guillory, Titan Robotics, Colorado Springs, CO

9:15 - 9:45 a.m.
Scanning Old Patterns and Creating New Patterns

Carl Berube, Celero Partners, Woburn, MA

9:45 - 10:15 a.m.
Laser Scanning Pattern Tools for Conversion to 3D CAD Models

Thomas Claus, Flowserve USA, Houston, TX

10:15 - 10:30 a.m.
10:30 - 11 a.m.
Hybrid and Tooled Printing

Doug Imrie, Southern Cast Products, Jonesboro, AR

11 - 11:30 a.m.
3D Printed Tools

Tom Renk, Alliant Castings, Winona MN

11:30 a.m. - Noon
Matchplates and Tools

Garrett Iverson, Scenic Industries LLC, Chattanooga, TN

Noon - 1:15 p.m.
Lunch & Meet With Exhibitors
1:15 - 1:45 p.m.
An African Experience: Challenges of Additive Manufacturing in a Foundry in Nigeria

Vassily Oye Barberopoulos, Nigerian Foundries Ltd., Lagos, Nigeria

1:45 - 2:15 p.m.
3D Printed Tools for Lost Foam Casting

Marshall Miller, Flowserve Corp., Irving, TX

2:15 - 2:45 p.m.
Statistical Analysis of Sand Molds and Castings From 3D Printed Plastic Patterns

Will Shambley, Metal Fish LLC, North Chelmsford, MA  

2:45 - 3 p.m.
3 - 3:45 p.m.
Direct Metal Printing Technologies for Metalcasting

Richard Huff, GE Additive, West Chester, OH

3:45 - 4:15 p.m.
FDM 3D Printing in Sand & Investment Casting

Marshall Miller, Flowserve, Irving, TX

4:15 p.m.
Ask the Expert Panel: Experiences and Trials Using 3D Printing for Tooling

Reverse Engineering & Creating 3D
Tom Claus
, Flowserve USA, Inc., Houston, TX

Nigerian Foundry for Printing Tools
Vassily Oye
, Nigerian Foundries Ltd., Lagos, Nigeria

Printing Tools
Garrett Iverson
, Scenic Industries, Chattanooga, TN

5 - 6:30 p.m.
Networking Reception and Table Top Exhibits
Thursday, September 13, 2018
8 - 8:15 a.m.
AFS Activities and Vision for AM Expendable Pattern Committee

Tom Mueller, Committee Chair; Mueller AMS, New Berlin, WI

8:15 - 8:45 a.m.
Are Printed Patterns Viable for Production?

Sharon Weaver, 3D Systems, Rock Hill, SC

8:45 - 9:15 a.m.
Casting Prototype PLA Investment Casting Patterns Built Using the Material Extrusion Process

Scott Reed, Flowserve Corporation, Dayton, OH  

9:15 - 9:45 a.m.
Printed Ceramic Patterns?

Tom Mueller, Mueller AMS, New Berlin, WI

9:45 - 10 a.m.
10 - 10:30 a.m.
Printed Patterns for Creating Monuments

Eyal Chernichovsky, FORM, Bezalel Academy of Art and Design, Portland, OR

10:30 - 11 a.m.
An Investigation Into the Effect of Hollowing Printed Investment Casting Patterns to Reduce Shell Cracking in the Autoclave

Tom Mueller, Mueller AMS, New Berlin, WI

11 a.m.
Development and Use of Printed Ceramic Cores Using a DLP Process

Bob Morris, Renaissance Services, Fairborn, OH

Special Events


Registration Fees

AFS Members: $750

Non Members: $1,125

Cancellations & Substitutions

Substitutions will be accepted anytime. However, cancellations of confirmed registrants with full refund of fees will not be accepted unless received at least two weeks prior to the conference date. In the unlikely event the conference is cancelled for any reason, AFS liability is limited to the return of the registration fee.