Sand Casting and Additive Manufacturing Conference

Everything related to sand casting and 3D sand printing in one place!

LIVE ONLINE AND ON-DEMAND
August 31 - September 3, 2020

Overview

AFS has combined the highly popular sand casting and additive manufacturing conferences into one big online event! Now, you can hear from leading experts on green sand casting and 3D printing without incurring any costs for transportation, hotels and meals. Using both live online and on-demand material, this conference will cover the latest advances in sand casting technologies as well as practical information that will help attendees improve their foundry processes. Learn how others are perfecting their sand casting operations and hear from founders who have successfully incorporated 3D printing into their sand casting process. This virtual conference will deploy the latest technology to deliver the highest-possible attendee experience – including the chance to submit questions and receive answers during a number of the sessions. Busy the days of the conference? No problem - all presentations will be available on demand at your convenience. Register today!

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Program, Speakers & Agenda Subject To Change

Location

  • LIVE ONLINE AND ON-DEMAND
  • August 31 - September 3, 2020

Conference Agenda

Monday, August 31, 2020
LIVE ONLINE
1:15 - 2:15 p.m. CT
(also available on demand)
KEYNOTE SPEAKER: Additive Manufacturing: Lessons Learned from the Covid-19 Pandemic -- Where do American Metalcasters go from here?

John Danko, Danko Arlington Inc. (Baltimore, MD)

Hear from an early adopter of 3D sand printing! Started just after the 1918-1919 Spanish Flu pandemic, Danko Arlington recently celebrated its 100th anniversary. John Danko, president of Danko Arlington, will discuss how additive manufacturing has transformed the foundry and the lessons learned while adapting to changing environments over the last century. Stressing innovation and out-of-the-box thinking, John will emphasize e-commerce, digital platforms, remote management, and 3D sand printing to best prepare metalcasters for the next generation.

John
John Danko
Tuesday, September 1, 2020
Session 1: Green Sand Casting
Session Chairs:

Bryan Kluge, Imerys (Cincinnati, OH)
Pete Gravunder, Badger Mining Corp. (Berlin, WI)

Bryan Kluge
Bryan Kluge
Pete Gravunder,
Pete Gravunder

 

LIVE ONLINE
8:30 - 9:15 a.m. CT
(also available on demand)
Foundry Case Study and live Q & A: New Sand Additions for Green Sand System

Travis Hepfner, Cadillac Casting Inc. (Cadillac, MI)
Michelle Ring, Minerals Tech (Carmel, IN)

Are new sand additions important to sand system quality? Listen to one foundry's story. With a big influx of heavily cored jobs at the facility, it didn't make sense to keep adding new sand when they were constantly removing sand from the system to better maintain levels. Learn how this foundry overcame the challenges created by this system change.

Travis Hepfner
Travis Hepfner
Michelle
Michelle Ring

 

LIVE ONLINE
9:30 - 10 a.m. CT
(also available on demand)
Green Sand Additives -- Why Should a Foundry Use Them?

Steve Neltner, REFCOTEC (Orrville, OH)

Hear from one of the leading sand system experts! This presentation discusses how green sand additives can greatly enhance the properties of prepared molding sand. Additionally, Neltner will discuss how foundries use specialty additives to create better sand property consistency, reduced casting cleaning time, and scrap.

steve
Steve Neltner
ON DEMAND
Green Sand Reclamation

Dave Silsby, Simpson Technologies (Aurora, IL)

Dave Silsby
Dave Silsby

 

ON DEMAND
Green Sand Testing

Larry Kaiser, American Colloid Company (Hoffman Estates, IL)

Larry
Larry Kaiser
Session 2: Additive Manufacturing - 3D Sand Printing
Session Chairs:

Jerry Thiel, University of Northern Iowa (Cedar Falls, IA)
Jiten Shah, Product Development & Analysis LLC (Naperville, IL)

jerry
Jerry Thiel
jiten
Jiten Shah

 

LIVE ONLINE
10:30 - 11 a.m. CT
(also available on demand)
Application of Sand 3D Printing for Stainless Steel Castings

Dr. Yoya Fukuda, Kimura Foundry America Inc. (Shelbyville, IN)

Yoya
Yoya Fukuda

 

LIVE ONLINE
11 - 11:30 a.m. CT
(also available on demand)
Advancing Developments for 3D Consumables -- Resin Systems, Coatings and Cleaners

Kelley Kerns, HA-International (Westmont, IL)

As the demands on printing technologies and capabilities advance, so do the performance expectations on the consumables. What you should expect from resin systems, cleaners, and coatings to optimize your operation? Hear a leading supplier discuss the latest technological advances.

kelley
Kelley Kerns

 

ON DEMAND
Silica Options Review

Doug Imrie, Southern Cast Products Inc. (Jonesboro, AR)

doug
Doug Imrie

 

ON DEMAND
Production-Speed 3D Printing with New Industry 4.0 Technologies

Rick Lucas, ExOne (Irwin, PA)

Rick
Rick Lucas

 

ON DEMAND
Design & Modeling of 3D Printed Sand Castings

Jiten Shah, Product Development & Analysis LLC (Naperville, IL)

jiten
Jiten Shah

 

Wednesday, September 2, 2020
Session 3: Chemically Bonded Molds and Cores
Session Chair:

 Dr. Scott Giese, University of Northern Iowa (Cedar Falls, IA)

Scott Giese
Scott Giese

 

LIVE ONLINE
8:30 - 9 a.m. CT
(also available on demand)
The Journey to Silica Compliance with Ceramics

Bill Johnston, Ellwood Engineered Castings (Hubbard, OH)

Learn from a foundry that has gone through the process of replacing silica sand with ceramic media. The presenter will walk through the full conversion process, from evaluating ceramic media for a possible foundry conversion, trials to evaluate the material, steps to make a complete conversion to a ceramic molding material, and lessons learned during and after the conversion.

 

LIVE ONLINE
9 - 9:45 a.m. CT 
(also available on demand)
"Ask the Expert” Live Discussion: Chemically Bonded Molds, Cores and Refractory Coatings (AFS Cured Sand & Aggregate Committee)

Sairam Ravi, University of Northern Iowa (Cedar Falls, IA)
Brodie Biersner, HA-International (Westmont, IL)

Bring your problems and questions on everything you need to know about chemically bonded cores and molds and refractory coatings. A panel of experts will answer your questions and help solve your most pressing problems in this area.

Ravi
Sairam Ravi
brodie
Brodie Biersner

 

LIVE ONLINE
9:45 - 10:15 a.m. CT 
(also available on demand)
Adoption of Inorganic Binders

Kelley Kerns, HA-International (Westmont, IL)
Joe Muniza, ASK Chemicals (Dublin, OH)

kelley
Kelley Kerns
Joe
Joe Muniza

 

ON DEMAND
Panel: Casting Trials & Analytics Using Disc-Shaped Sand Specimens to Study Mold-Metal Interface Reactions

Dr. Sam Ramrattan, Western Michigan University (Kalamazoo, MI)
Jeff Cieplewski, Weaver Material Services, Inc.
Dr. Lee Wells, Western Michigan University (Kalamazoo, MI)
Andy Pike, Mueller Co.

Dr. Sam Ramrattan
Dr. Sam Ramrattan
Jeff Cieplewski
Jeff Cieplewski
Dr. Lee Wells
Dr. Lee Wells
Andy
Andy Pike

 

ON DEMAND
A Casting Trial to Evaluate Various Chemically Bonded Sand Disc-Shaped Specimens for Surface Finish and Erosion Defects

Milan Rival, Altair Engineering, Inc. (Troy, MI)

Many foundries prefer chemically bonded sand mold over green sand when it comes to castings with thin-wall sections and complex internal dimensions, yet casting issues can result in costly defects. This presentation addresses chemically bonded sand erosion and surface finish issues for aluminum and cast iron castings. Erosion in chemically bonded sand can occur when molten alloy dislodges grains of sand, resulting in a rough as-cast finish.

milian
Milan Rival
ON DEMAND
Simulation of the Core Blowing Process

Dan Coyle, Magma Foundry Technologies (Schaumburg, IL)

Dan Coyle
Dan Coyle

 

ON DEMAND
High Temperature Strengths of 3D Phenolic Printed Molds and Cores

Sairam Ravi, University of Northern Iowa (Cedar Falls, IA)

Ravi
Sairam Ravi

 

ON DEMAND
Ceramics, A Value Beyond OSHA PEL Compliance

Claude Krause, Carbo Industrial Technologies, Broussard, LA

Claude
Claude Krause

 

Session 4: Additive Manufacturing—Printed Hard Tooling
Session Chairs:

Kirk Rogers, Case Western University (Cleveland, OH)
Kip Woods, Emerson Process Management (Nevada, IA)

kip
Kip Woods

 

LIVE ONLINE
11 - 11:30 a.m. CT
(also available on demand)
Printing Patterns and Core Boxes

Clay Guillory, Titan Robotics Ltd. (Colorado Springs, CO)

clay
Clay Guillory

 

ON DEMAND
High Performance Additive Manufacturing Thermoplastics for the Foundry Industry

Alan Franc, Techmer PM (Clinton, TN)

The production of foundry tooling has been adopting additive manufacturing (AM) as a fabrication method. Conventional fused filament fabrication is the most common AM production process but is typically limited in types of materials available. These materials (such as PLA and ABS) have relatively poor abrasion and chemical resistance. This presentation will discuss and compare several thermoplastics composites with improved performance for foundry tooling.

Alan
Alan Franc

 

ON DEMAND
A Continued Investigation of the Viability of Printed Lost Foam Tooling

Marshall Miller, Flowserve Corp. (Rock Springs, GA)

The current cost of molds is a barrier to access of customers to the lost foam casting process. By applying new additive processes and materials through the AFS project to develop lost foam tools in polymers and titanium, the cost of tools is reduced to a fraction of the cost of subtractive tools.

marshall
Marshall Miller

 

ON DEMAND
The Application of Additive Manufacturing in the Lost Foam Process

Marshall Miller, Flowserve Corp. (Rock Springs, GA)

marshall
Marshall Miller

 

Thursday, September 3, 2020
Session 5: Environmental, Health & Safety
Session Chair:

Jeff Krause, HA International, Westmont, IL

jeff
Jeff Krause

 

LIVE ONLINE
8:30 - 9 a.m. CT
(also available on demand)
Management of Anime Exposure in the PUCB Core Room

Jarek Olszak, Laempe-Reich (Trussville, AL)

Jarek
Jarek Olszak

 

LIVE ONLINE
9 - 9:30 a.m. CT
(also available on demand)
EHS Aspects of 3D Sand Printing -- Air Quality, Ventilation and Limits on FA

Jeff Krause, HA International (Westmont, IL)
Kip Woods, Emerson Process Management (Nevada, IA)

jeff
Jeff Krause
Kip
Kip Woods

 

LIVE ONLINE
9:30 - 10 a.m. CT
(also available on demand)
Sand Processing Methods Show Reduction of Respirable Silica for the Foundry Industry

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

jerry
Jerry Thiel

Registration

Registration Fees

Early Registration: (Ends August 1st, 2020)
Non-member: $900.00 | Member: $600.00

Standard Registration:
Non-member: $1,080.00 | Member: $720.00

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.

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