Good Morning, Michael...
When I pickup the 3D printed output, I'll smooth out any small ridges, etc., manually. The 3D printed output will go to the foundry directly. The foundry will make a split impression in green sand. The split will be made at the chamfer line. If the foundry is not busy they can cast 1-3 prototypes in a couple of hours. The cast result is returned to me and I test them and sometimes bring in a variety of professional pitchers of varying ringer averages (20%-70%). They test the shoes and help me decide if I go into production. I have to send one of the prototypes to the National Horseshoe Pitching Assn. Two directors have to approve the design based on specifications developed. If I go into production, I send the cast or printed prototype to a patternmaking shop (Galena, Ill.) to make a split mold. The patternmaker makes two molds by splitting the horseshoe at the chamfer line. These are permanent molds made from aluminum. The split molds go to the foundry for production casting. This is not an inexpensive process, so, you don't want to make a mistake in the acceptance by the pitching fraternity. NHPA charges $300 for the first year license. The patternmaker charges ~$1,000 per split mold. There is also the cost of casting in ductile iron. I don't make any money from designing and producing horseshoes. It's basically a labor of love and a retirement project. It began with a belief that I could do things with 3D design that were not available to the traditional methods of creating horseshoes.
The only other way to produce horseshoes is drop forging. Unfortunately, it is much more expensive to create the molds and most drop forging is now done in China. I was only interested in a U.S. produced product.
Finally, there are some raised characters on the previously attached prototype that I'll emboss for the final 3D output. A foundry does not like vertical sides on anything, thus, the need for filleting and chamfering everything.
Regards...Bob
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