Supernova Award Category
Matrix Commerce
The Problem
Humtown was approached by the Youngstown-Warren Regional Chamber (Ohio) with a big project: Create a larger-than-life-size bobble head statue of a prominent figure to showcase the speed and cost-effectiveness of 3D printing for rapid prototyping, using sand, metal and plastic, to highlight the manufacturing innovation and high-tech capabilities of companies based in the Mahoning Valley region (northeast Ohio and northwest Pennsylvania).
Because the project was under a tight deadline, (from design to fabrication and delivery in less than one month) Humtown realized that using traditional tooling process would be too costly and time-intensive, as tooling typically takes 10-12 weeks to complete, and instead embarked on a rapid prototyping solution via an Industry 4.0 approach.
The Solution
Due to the tight deadline, the decision was made to leverage 3D printing/additive manufacturing capabilities. The bobble head project was an opportunity for Humtown to showcase how a 50-plus year old job shop can embrace new next-gen manufacturing techniques to rapid prototype via 3D sand printing. Production involved printing the body in pieces with fiberglass-reinforced sand, assembling the body, and finally coating it in aluminum. The project took only 2 weeks to produce, utilizing 225 man-hours. Humtown estimates the cost was 10x less than the cost if using a traditional tooling approach.
A collaboration between Humtown Products, Youngstown-Warren (Ohio) Regional Chamber of Commerce, Freshmade 3D, a Youngstown, Ohio-based 3D printing service bureau, and Youngstown State University, the project, showcased American manufacturing and innovation at its finest, the power of partnership between industry and academia, and the promise of rapid prototyping.
The results
The goal was to showcase how additive manufacturing is transforming the industry for the future. Humtown is leading the charge in reinventing the manufacturing industry by recognizing the possibilities with 3D printing and embracing the opportunities to enhance its competitive edge. The project also highlighted the power and potential of collaboration with the local government, manufacturing companies and educational institutions to drive adoption of innovative next-generation approaches in manufacturing.
Humtown was willing to take on any project to help show how progressive the company is and what it has to offer with new technology. The project has elevated the company’s competitive position and its presence in the market by showcasing its agility and forward-thinking, providing an impressive showing for the OEMs Humtown works with.
In an age where manufacturers are challenged to recruit and retain Millennial talent, this project has positioned Humtown as an innovator, pioneering “what’s next” in manufacturing, giving the company a competitive edge in talent acquisition.
Metrics
The recognition and visibility that Humtown has gained from the project has brought new clients and new business to Humtown.
Just three months after the production of the bobble heads, Humtown announced it had expanded its 3D mold manufacturing operations in Leetonia, Ohio, which will also serve as a hands-on classroom for Youngstown State University engineering students, training them how to produce molds and patterns using 3D printing technology.
The Technology
3D printing equipment - ExOne S-max sand printer; ERP solution: Epicor ERP; Control/Automation System: Siemens Factory automation; MES solution: Basecamp Project Management
Disruptive Factor
Humtown survived major financial upheavals in 1990, 2000, and 2009 when industry as a whole was off by 65%. Humtown did what it had to do to survive – laying off the vast majority of its employees, with the plant shrinking from 200 employees in December 2009 to 20 workers only 2 months later.
Since then Humtown has reinvented itself and enhanced its competitive position, actively embracing next-generation technologies such as additive manufacturing to offer a wider range of capabilities to its customers. Humtown Products is a member of America Makes, the nation’s leading and collaborative partner in additive manufacturing and 3D printing technology research, discovery, creation and innovation. And since the National Additive Manufacturing Innovation Institute was established in 2012, the area has become the center of additive manufacturing.
According to Humtown President and CEO, Mark Lamoncha, 3D manufacturing has helped revive Humtown: “If you don’t move with the technology you’ll be run over by it. We need to be 3D thinkers today.” Lamoncha also feels additive manufacturing and 3D printing is helping evolve the region that runs through Pittsburg to Cleveland from “Rust Belt,” to “Tech Belt.”
The project also has helped advance the futures of the next generation of manufacturing talent – helping university students apply the latest innovations to real-life manufacturing applications.
Shining Moment
Since the announcement of the 3D printed life-size bobble heads, the project has gained world-wide visibility with more than 50 media outlets around the world covering the story. The Danish Broadcasting Corp. approached representatives from the Youngstown/Warren Regional Chamber to make a documentary on the project. The Chamber representatives also reportedly met with Japanese singer Yoko Noge Dean, and Toyoki Nakanishi from the Nikkei Asian Review.