Prototype New Professional Horseshoe Design

[Photon713]

Good Evening, all...
I am developing a prototype for a new professional horseshoe. I need just one for testing. I need to find the cheapest way to provide just one copy, be able to test it and make modifications if necessary. In general, horseshoes are cast. Recently, I saw a video of the Torchmate CNC Cutting System and could work with a 1/4 inch thick cutout for testing. The final would have 1 inch thick tips, but, for the prototype 1/4 would suffice. I've also considered casting as a possibility or perhaps welding to an existing horseshoe. I need suggestions, i.e., cast?, cnc cutout?, or welding? Perhaps there are other choices I've not considered. Any suggestions and a direction to the proper forum appreciated. Would I save costs if I provide the CNC instructions? Thanks

[mc-motorsports]

3d printing if you just want something to hold, if a plastic model would be ok, but I'm guessing you want a metal shoe that you can throw. If it's not too much diffrent from an off the shelf shoe, weld it!

[Photon713]

Thanks you, mc-motorsports.

I'm attaching what would be typical of my starting point. There is material to be added to the inside and material to be removed from the outside. A gentleman with some welding experience expressed some concern with welding an addition on the inside. The majority of horseshoes are cast.
Thanks for looking.

[mc-motorsports]

Maybe mill it out for the first one. Cast iron or cast steel? Depending on the carbon content, it's going to be somewhere between simple and impossible to weld them up. Then if you had a CAD file, you'll have an ultimate starting point should you choose to go into production. And it would probably be faster to just mill a set out vs. a lot of welding and grinding. Too much manual labor for me! lol! But seriously, I'm a certified welder, GTAW and SMAW, I vote to mill them.

What do you have to start with?

[Photon713]

Thanks, mc-motorsports...

The JPEG I've included is what I have to start with or something similar. I don't know the type of metal cast. I also do not know what you mean by milling? I regret that I am a total novice in this area. Do you have any idea what ballpark cost we're talking about -- milling? I've wondered if creating a mold and casting with a lower temperature metal would be cost effective? After I have the shoe in hand, I'll be testing it with high speed video. Thank you for your interest....regards.

[mc-motorsports]

Milling as in Milling Center or Milling Machine, cutting a billet of steel with drills and endmills for instance. Seems like a lot of work to cast the first one. And how do you make a sand mold without a master? I'm not a casting guy, just took interest in what your doing.

But if it was me, I would mill one out of billet steel. Cost can vary greatly depending upon the level of detail you want, for instance,
perfectly rounded corners (machine precision) or just grind a nice radius using an angle grinder?
What are a couple of rough dimensions? I only have a clue as to how big a horseshoe is... 8" X 6"?
How thick?
Do you have a pic of the side profile?

I'll quote it if you'd like. And you can also post up in the RFQ section and get other bids. But more info is needed, actually, everything you can post up, blueprints if you have them! Otherwise, front, back and side profile pics with basic dimensions. Hell, I'll even draw it in CAD for ya if I'm bored tomorrow night if you can post up enough info! No garantee though, I have no clue what the day holds in store.

[Superman]

If the part is to be flat on both sides i.e. 1/4" plate

I would then suggest water-jet or plasma cutting the shape out of plate steel, it's quick, clean, cheaper that fully machining a part. A quick run with a grinder or linisher to finish dress it

water-jet is cleaner cutting than plasma

[mc-motorsports]

That part doesn't look flat to me. The ends look offset, which could be done with a huge press. But that's why I ruled out plasma or waterjet or 2d cutting.

[metalcaster4jc]

make exactly what you want out of plywood, add a bit to the dimensions to allow for shrinkage and UPS it to me, I'll have you a cast ductile iron part within 4 weeks.

[Photon713]

Good morning, mc-motorsports and Superman...

The National Horseshoe Pitching Association has developed a set of guidelines which I would need to adhere to.
Length no greater than 7.625 inches (7-5/8 in.)
Width no greater than 7.250 inches (7-1/4 in.)
Front opening no greater than 3.50 inches (3-1/2 in.)
Height no greater than 1.0 inches.
Horseshoe cannot exceed 2 lbs 10 ozs. (no minimum)
The horseshoe stake for professional competition is 1 inch in diameter.
Any design must be approved by the NHPA. I am hoping that the members of this forum can recommend a quick way to create a prototype in a material that permits live testing. Further, the ability to modify the design and create a new prototype. My primary concern is the inner design and what happens when the horseshoe strikes the stake. Thus, I would be able to work with a 1/4 inch thick cutout. However, this is a personal venture to help the flip style horseshoe pitcher particularly Elder qualified (70+ years old) pitchers.
Consequently, I am looking to the professionals on this forum to give me some idea as to the best approach as well as the least costly method of creating quick prototypes. I can come up with a master for molding and casting using a polymer clay which hardens when heated. I am hoping to capture the characteristics of impact with high speed video. Any suggestions will be most welcome..Thank You in advance. You can contact me directly at bobrass at verizon dot net .

[metalcaster4jc]

I could probably make a couple of the ductile iron prototypes from the polymer clay master.

[Photon713]

Good Afternoon, metalcaster4jc...

Thank you for the offer. Please contact me offline at bobrass@verizon.net
for your mailing address and cost for the casting. It shouldn't take too long to gen up a master. Regards