Attending a lab tour of the CIRAS Digital Manufacturing Lab Powered by Alliant Energy proved invaluable for Mid-States Steel Corporation when they faced a critical equipment issue. “It was a great use of our time,” said Duane Vander Weff, purchasing manager. “The tour exposed us to technologies we wouldn’t usually encounter, which proved crucial when we needed them most.”
The company’s trouble began when the drive gear in their older paint mixing system wore out. This resulted in Mid-States Steel manually mixing paint with no replacement available, delaying other essential tasks. “Like many companies, staff availability and capacity are limited, and this setback slowed us down,” said Vander Weff.
Having attended the tour, Vander Weff remembered a story about using 3D printing to recreate a gear. “When our gear failed, I immediately thought of CIRAS and reached out. I’m glad I attended the tour and recommend that other companies do the same.”
After the company contacted CIRAS, Chris Hill, CIRAS engineering services director, promptly responded. He was on site within a few days to begin the review and present potential solutions. The biggest challenge was the lack of a 3D CAD model for the gear, which was severely worn. Hill proposed leveraging the CIRAS 3D printer to efficiently create a test gear.
Though the initial gear didn’t fit perfectly due to irregular holes in the mounting plate, Hill used a laser scanner to map the hole pattern, adjusted the CAD model, and produced a better fit. Two days later, the company had a working test gear in place while the final version, made from durable nylon and carbon fiber, was printed. CIRAS also provided two spare gears and a 3D CAD model for future use.
“We appreciate the extra effort from CIRAS. We now have spare gears and a model for future production, and we’re confident CIRAS can help with similar issues,” said Vander Weff.
Reflecting on the project, Vander Weff stressed the value of CIRAS in helping Iowa companies access cutting-edge technology. “It’s tough to stay current with trends outside our core business, but CIRAS provided new possibilities and insights. We’ll definitely be working with them again.”
For more information, contact Chris Hill at chhill@iastate.edu or 515-313-8251.