Increasing manufacturing competency with a 'dirt-cheap' sand casting lab

Abstract

The Society of Manufacturing Engineers Education Foundation has identified competency gaps in a number of critical areas including manufacturing processes, materials, and teamwork. To address these problem areas and provide students with a hands-on manufacturing experience, an economical sand casting lab was developed and implemented in an industrial processes course at Oklahoma State University. The lab exercise familiarizes students with the sand casting process using inexpensive and readily available materials and equipment. A key variation is that wax is substituted for metal as the casting medium. This change greatly increases process safety while significantly decreasing the cost. The final product, a votive candle, can be retained by the students as a reminder of their experience. More importantly, while conducting the lab in teams of three, students are confronted with issues related to materials and manufacturability, process improvements, teamwork, and following procedures. Although this lab is currently being utilized with college juniors and seniors, it could also be an appropriate activity for high-school students to learn more about manufacturing processes and related issues. The paper also suggests ways in which the sand casting lab could be expanded to address additional competency gaps such as manufacturing systems principles, ergonomics, and quality.