Appendix I - Pattern Making Procedures

Patternmaking Procedures ---------------------------------------------------------------------------------------------------------------------

DOUBLE MATCH-PLATE PATTERN

IKBNT Foundry Lab 2011AI-1

Step 1: Tools and materials preparation.i) Prepare tools and materials to make a

pattern.ii) Sketch the outline design on the wood

plate.iii) Cut the wood (roughly) following the

outline design.Equipment: Steel ruler, vernier caliper, measuring tape, band saw and pencil.

Step 2: Pattern (product) preparation.i) Carve the wood following the outline

design.ii) Use carving tools set, sand paper, sanding

machine, wood lathe, saw and file to make a pattern.

Step 3: Match-plate pattern preparation.i) Use plywood to fabricate the match-plate.ii) Using wood bond, attach the solid pattern

to the match-plate.iii) Attach the well, runner sprue and riser on

the determined locations accordingly.

Step 4: Finishing.i) Use the putty filler to repair any hole or

rough surface.ii) Use sand paper to finishing.

Patternmaking Procedures ---------------------------------------------------------------------------------------------------------------------

Double Match-Plate Pattern

FRONT VIEW

BACK VIEW

IKBNT Foundry Lab 2011AI-2

Product pattern

WellMatch-plate

Runner

Core housing

Wooden sprue and/or riser

Core housing

Match-plate

Core housing

Core housing

Product pattern

Patternmaking Procedures ---------------------------------------------------------------------------------------------------------------------

SPLIT PATTERN

IKBNT Foundry Lab 2011AI-3

Step 1: Tools and materials preparation.i) Prepare tools and materials to make a

pattern.ii) Sketch the outline design on the wood

plate.iii) Cut the wood (roughly) following the

outline design.Equipment: Steel ruler, vernier caliper, measuring tape, band saw and pencil.

Step 2: Pattern (product) preparation.i) Make the shape following the outline

design using jig saw.ii) Use file and sand paper to refine the

surface finish.iii) Split the pattern into 2 using band saw at

the center of the pattern.Equipment: File, jig saw, sand paper and band saw.

Step 3: Pattern dowel and guide holes.i) At one side of the pattern, drill the guide

holes at the determined locations.ii) At the other side, attach the dowel at the

determined locations.

Step 4: Finishing.i) Use the putty filler to repair any hole or

rough surface.ii) Use sand paper to finishing.

Patternmaking Procedures ---------------------------------------------------------------------------------------------------------------------

Split Pattern.

PATTERN (SPLIT)

PATTERN (COMBINED)

IKBNT Foundry Lab 2011AI-4

Wooden dowel pin

Guide holes

Product pattern

Product pattern

Patternmaking Procedures ---------------------------------------------------------------------------------------------------------------------

SINGLE MATCH-PLATE PATTERN

IKBNT Foundry Lab 2011AI-5

Step 1: Wood preparation.i) Select the type of wood available for

patternmaking process in the laboratory or workshop.

Step 2: Tools and materials preparation.i) Prepare tools and materials to make a

pattern.ii) Sketch the outline design on the wood

plate.iii) Cut the wood (roughly) following the

outline design.Equipment: Steel ruler, vernier caliper, measuring tape, band saw and pencil.

Step 3: Match-plate and product pattern preparation.i) Carve the wood following the shape using

carving tools set, files, sand paper and sanding machine.

ii) If the shape is cylindrical, use wood lathe machine.

iii) At the front view of the previously prepared match-plate, attach the product pattern using wood bond.

Step 4: Gating system preparation.i) At the back view of the match-plate attach

the gating systems (well, runner, gate and etc.) at the determined locations.

Step 4: Finishing.i) Use the putty filler to repair any hole or

rough surface.ii) Use sand paper to finishing.

Patternmaking Procedures ---------------------------------------------------------------------------------------------------------------------

Single Match-Plate Pattern.

FRONT VIEW

BACK VIEW

IKBNT Foundry Lab 2011AI-6

Product pattern

Match-plate

Well

Runner

Ingate (3 places)

Runner for risers (3 places)

Wooden sprue and/or riser