They Make Patterns For Part Casting

They Make Patterns For Part Casting Need a part cast for a restoration, a new build, or to start manufacturing parts? To cast a part, you need a mold, and to make a mold, you need a pattern. Raber Pattern Works has been making patterns from wood and, more recently, aluminum and polyurethane, for nearly 50 years.  “There aren’t many left who make patterns like we do,” says Allen Raber. “Wood can be used to make a mold for casting a part, but wood has a tendency to crack as it absorbs moisture over time. A two-part poly mixture or aluminum pattern will hold up better over time for repeat molding.” Every pattern starts as wood. If repeated molding is part of the plan, the wood pattern will be used to create a poly or metal match plate. Raber and his brother Abraham have taken over management of the firm in recent years. They still use the same woodworking techniques and equipment their father, Emanuel, learned in his father’s furniture shop during the 1960s and 1970s. However, the Rabers are looking forward to adding new techniques and technologies in the near future. “We want to get into AutoCAD software for designing and 3D printing for making the patterns,” says Raber. “Some of our customers prefer wood for the way it draws out of the sand mold. However, if you understand the casting process and know what you’re doing, the new technologies work as well.” It’s that knowledge that Raber feels sets the family business apart. Initially, what became Raber Pattern Works was part of what is now the Clark Casting foundry. Today, the two are operated separately by Raber cousins. “We still work together,” says Raber. “A lot of our pattern work goes to them, but we also work with other foundries.” Understanding how the foundries make their molds and castings with Raber Patterns is key to how the patterns are made. Whether simple or complex, each pattern starts with specific dimensions and designs. Past projects have ranged from toilet paper holders to scale-model toys and parts for full-size and scale-model steam engines. One job was to create a pattern for a 13-ft pilaster (trim) for a Washington, D.C., storefront doorway. Another was to make a pattern for stair treads for a spiral staircase for the Washington Aqueduct. “People will call and ask what it costs to have a pattern made,” says Raber. “Having the actual part in hand is the best option. However, if they can provide pictures and dimensions, I can usually give a ballpark estimate.” If a part is worn, broken or severely corroded, Raber may need to estimate the original dimensions. The type of metal to be cast and the rate of contraction during cooling must also be considered. The estimate will also depend in part on the type of material used for the pattern. A much bigger factor is the piece’s complexity. Does it involve interior core boxes? Core boxes create cavities within the mold. “One of our most complex projects was a pattern for a cylinder block for a Stanley Steamer automobile,” says Raber. “It involved five different core boxes that all had to interlock within the pattern to form the insides of pistons and the water jacket.” Another complexity involves the type and amount of machining to be performed on the final part. “Everywhere there’ll be machining done, we have to add to the pattern to ensure space in the mold for extra material to be machined.” Raber’s hand-cranked Fry Pie Press is a good example of their pattern-making. They originally made the patterns for the stainless-steel press and later bought the rights and inventory to market it themselves. The machine accepts five dies with four patterns to tailor the pie to the occasion. Through direct retail sales and a dealer in Texas, the Raber Fry Pie Press has been sold in all 50 states and 18 countries. A recent Facebook Reel from a customer went viral, further boosting interest. Contact: FARM SHOW Followup, Raber Pattern Works, 2966 Twp. Rd. 163, Baltic, Ohio 43804 (ph 330-897-1257; raberpatternworks@sle.email).

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