AFS Corporate Member The Rock Island Arsenal-Joint Manufacturing and Technology Center has set a new benchmark in its foundry operations: On June 6, the team successfully poured the largest part produced in at least two decades, if not ever—underscoring the facility’s advanced capabilities.

“This is a proud moment for all of us at RIA-JMTC,” said Jamie Morris, division chief of hot metals. “Producing such a massive part required precise coordination, advanced technology, and a relentless commitment to quality. This achievement is a testament to our team’s skill and dedication.”

The historic casting, a pintle system for a lock and dam in Pennsylvania for the Corps of Engineers, weighs 7,125 lbs. The mold for the casting comprised 16 distinct pieces, all of which were sand-printed at RIA-JMTC. This technique allowed for the precise creation of intricate mold components and enhances the accuracy of the final product. It also significantly reduces production time compared to traditional methods.

“The successful pouring of the pintle system showcases our capability to handle large-scale projects with precision,” said Shane Mattson, laboratory and process development and foundry production controller. “The integration of sand printing technology has revolutionized our approach, allowing us to meet and exceed the high standards required for such critical components.”

The team dedicated eight days to print all the components necessary for the mold. The resulting part exceeded the stringent specifications set by the Corps of Engineers.

“This project was a significant undertaking, and our team rose to the challenge admirably,” added Silas Gambleton Jr., RIA-JMTC foundry branch chief. “Their hard work and collaboration have paid off in a big way, and we couldn’t be more thrilled with the outcome.”