Danko Arlington Steers the Warfighter with New Additive Technology

3-D Sand KC-135 Steering Wheels

VX1000 Picture with Job BoxVoxeljet Logo

KC-135 Stratotanker1KC135 Cockpit and steering wheel

January 22, 2018

Within days of installing its new 3-D sand printer, Danko Arlington is already producing complex molds and cores, including some used for casting KC-135 steering wheels.

Developed by Boeing in 1956, the KC-135 is used for aerial flight refueling.  Even though the plane will soon be replaced by the newer KC-46A, it is expected to be used until 2040.  Like many older planes, ships, and military vehicles, KC-135’s are constructed of thousands of parts produced from legacy tools and fixtures that are worn-out, expensive and difficult to procure — especially in small quantities.

For the past eight years, Danko Arlington has pioneered the use of 3-D fused deposition modeling (FDM) printing to create plastic foundry tooling. Sand with binder is rammed around the pattern, then removed to form a mold cavity.  Molten is then poured in the molds to produce a casting.

The company’s new VX1000-PDB sand printer now bypasses the need for foundry tooling entirely.  Perfected by Voxeljet AG in Germany, the PDB sand process uses a robotic machine to precisely lay resin onto tiny layers of sand which are fused together with infrared heat.

3-D sand printing is just in its infancy.   It will no-doubt disrupt military and commercial casting supply chains.  In addition, it will enable casting prototypes, short runs, and even futuristic designs that could have never have been made from conventional tooling to be printed quickly and efficiently without human hands.

Danko Arlington is excited to steer the course ahead!

Danko Arlington invests in 3-D Sand Printing

Voxeljet VX1000


Voxeljet Logo




January 2nd 2018.  Danko Arlington, Inc., the American Foundry Society’s Metalcaster of the Year, is excited to announce the installation of its first 3-D sand printer.

Designed and made by Voxeljet AG in Germany, the new VX1000-PDB is the first of its kind in the USA.  PDB stands for phenolic direct binding.  Voxeljet’s unique printing process uses a 300dpi printhead to selectively eject glue on a thin bed of sand.  An application of infrared heat then cures the glue to literally build-up a solid mold, layer by layer in sand.  Sand molds are used for metal casting because they do not burn.   After printing, any unbound sand is 100% recycled and reused in the PDB process.   After metal casting, the solid PDB sand molds can be crushed and thermally reclaimed in the company’s existing sand recycler.

The additive process eliminates the need for a die or pattern to create a mold cavity. The traditional sand casting process dates back over five thousand years ago to the Bronze Age.  This technological advantage now enables engineers to design metal castings on the computer then have the printer make the sand molds automatically.  With 3-D sand, molten alloys can be poured to custom shapes within hours instead of allowing weeks or months for time to make traditional tooling.

For years, the VX1000 has been a proven platform for printing plastic models and molds for the investment casting process using PMMA (Poly methyl methacrylate) material.  With the adaption of the machine now for sand, printing layer thicknesses of approximately 300 µm or .012” will allow for incredibly high accuracies. The machine’s printing envelope of 1000mm x 600mm x 500mm (39-3/8”x 23-5/8” x 19-5/8” high) is ideal for quickly manufacturing medium sized components, function prototypes, and complex sand cores.

Danko Arlington has recently renovated and dedicated approximately 5000 square feet of its original pattern shop constructed in 1945 to house this new state-of-the art equipment.  The new Additive Manufacturing (AM) center will also house the company’s two large Stratasys Fortus 900mc 3-D printers which have been producing polycarbonate patterns and core boxes since 2010.  This next-generation AM center will be the first of its kind in the foundry industry — allowing customers, engineers, artists, and students to access this incredible next-generation technology in Northwest Baltimore City.

Danko Arlington looks forward to inviting commercial and military customers, founders, manufacturers, educators, and local legislators to formally showcase its new AM center in the Spring of 2018.

For more information watch this video:  Phenolic-Direct-Binder Process – YouTube

Danko Arlington Participates at UMD Fall Design Day

UMD Engr Logo

On Tuesday, December 5th, John Danko was honored to be a guest judge for the Department of Mechanical Engineering’s Design Day at the University of Maryland.

Twenty-nine senior design projects were showcased this semester at the Jeong H. Kim Engineering Building Rotunda in College Park.  Teams of Senior ME students presented prototypes built to solve engineering problems as a part of the Integrated Product and Process Development course, ENME472. Judging criteria includes professionalism, prototype quality and presentation.   This year’s judged projects included a device which shapes K2M MESA rails for the use of scoliosis corrective surgeries, an elevating shopping cart to reduce user effort, and a diffuser to be installed in older septic tanks to meet newer Maryland environmental standards.

Danko Arlington values the opportunity to connect with engineering students, particularly with UMD Design Day and SME Baja.  As one of the Maryland’s leaders in additive manufacturing, the company looks forward to helping students learn about rapid casting techniques as well as providing new job opportunities at its Baltimore City operation.

Christopher’s Place Employment Academy Graduation Speech

Catholic Charity Logo

The following is the text from Danko Arlington President John Danko’s remarks to recent graduates from Christopher’s Place Employment Academy, 25 Fallsway, Baltimore, Maryland 21202, Thanksgiving  Week, November 21, 2017.

Good afternoon. Thank you for inviting me.  I have been to Christopher’s place many times, but never had the opportunity to present to a graduating class. It’s not every day that one has an opportunity to share a few words with such an inspiring and diverse group.

I say inspiring, because you have overcome the odds to be where you are today.  Against great adversity, hardship, challenges, and tough barriers. So, congratulations.  I wish you the best of luck in your future!  I only have a few thoughts to share with you today.

As an employer of ex-offenders, I am often asked why we hire second chance applicants.

Why we do it is because it simply is the right thing to do.  Our company is located in Northwest Baltimore – an area which desperately needs jobs.    Personally, I have had only had one job in my entire life, and it is working at Danko Arlington – now full time for over 31 years, 37 years if you count my summer jobs in high school and college.   To inherit a corporation as the next generation bears much responsibility.   I am grateful for my mom and dad to teach me the humbling value that, “to much is given, much is expected.“

This inheritance also complements my Christian faith.  And as Christians, we learn that faith must be put into action, even in the working world.  What a better way to do both –working at the company and putting faith into action. Can this be done?  A recent canonized saint of our time, Saint Teresa of Calcutta said that it could.   Mother Theresa once remarked about her dear famous and wealthy friend, Princess Diana, that we are all called to action.  It does not matter if you are a princess living in a castle, she said, we all are entrusted with the same responsibility of faith.   Managers too also have this same responsibility.  We are all called to be love our neighbors and even co-workers as ourselves.

Our Christian faith teaches us that when we die, we will be judged.   When we are judged, we will not be judged on how much money we earned, our company’s balance sheet, where we lived, what kind of school we attended, or what kind of car or house we owned. Rather, we will be judged on “I was hungry, and you gave me food.  I was thirsty, and you gave me drink.  I was sick, and you comforted me.  Naked, and you clothed me.  I was in prison, and you came to visit me.”  And perhaps, I was down-and-out, unemployed, and unemployable, and you gave me a break – you gave me a job.   What ever you do for the least of my brothers and sisters, you do for me.

When I was in my mid-twenties, I was also influenced by the politics of that time.  During the late 1980’s, I was greatly moved by a slogan coined by our forty first President, George H. Walker Bush — the first Bush President.   He came up with the notion of a “thousand points of light.”   This is where individuals, faith based groups, non-profits, churches, communities, and corporate America pitched in to make our country a better place.   Helping those in need was not the sole responsibility of Government, but responsibilities for you and me –like Catholic Charities and Christopher’s place.    We are all shining stars in this room – glistening and gleaming.

So here we are among so much brightness.  I am so proud of you!  Again congratulations! So where do you go from here?

As graduates, you will soon be entering the working world, that unlike your previous life at Christopher’s Place or in a recovery institution or behind the fence, you will not be provided and cared for.   Its all up to you how you succeed.

Companies like mine that hire ex-offenders are very forgiving and patient.  We understand that you are getting back into the workforce.  We give lots of second chances.  Third chances.  Fourth Chances.  But you have to be willing to improve. You have to be willing to overcome the internal and external barriers to keep going.  In our case at Danko Arlington, the lack of success with our ex-offenders are not the result of our efforts.  Rather it is the fault of the newly hired-ex-offender who starts to be late, leaves early, lies, eventually does not show up for work, and gets back in trouble again.

Years ago, when this happened, I used to get in my car, drive to the employee’s residence and knock on their door.   Most of the time, the employee was not there, or if they were, did not come to the door.   I should not have to do this, but I did so, because I cared and wanted our hires to succeed.  I and am so busy now, that I stopped this years ago.   To put in simply, your future job and your success is up to you.

The most important part of your future job is to show up – to be there and be on-time.   I can’t tell you how many employers like ours have this problem.   Not just with ex-offenders, but with everyone these days.   So, Rule #1 — be there!  Be on time too! Don’t leave early, and work a full week for a full-week of pay.  So many times, new hires miss time, then ask for a raise.  Why not just work your full forty hours to start out, then ask for a raise?

Actually, to be on time and working a full week is Rule #2.  Rule #1 precedes this.   Rule #1 is what you should be doing right now.  That is finding a job, and not just any job, but one you like.   Often, we see the job application process is like a factory worker standing on an assembly line.   In front of you are job opportunities that come by on the belt, and you pick and choose what comes up.    This is important, but not as important in picking the job, or seeking the job which you our like to do!    The secret in happy and long employment is to find a job that you will be willing to get up and go to work each day and enjoy.   Hard to believe, but this is more important than wages.   Don’t just get a job for the pay.  Get a job for what you like to do.  I you like to cook, find a job in a kitchen.  If you like to work with your hands, find a trade in construction, if you have a great voice, find a job singing.  But if you do not have a good singing voice, do not apply to be a singer!   Do some soul searching and come up with a job that you will like to do.  Then do your search. Most employers will train entry level workers for advancement, so ask how you can grow with that company, if you take a beginner job.

Please also keep in mind that you have been out of the workforce loop for some time, and as you are a starting over, it will take some time to work up to another level.   Often time, we see our re-entry employees frustrated, jealous, and envious of co-workers who advance in front of them.

Frustration is common among those in re-entry.  Perhaps it because one starting all over, the pay is not that great, no seniority, and you have more responsibility more than ever.   This frustration often leads to despair.   Avoiding despair is Rule # 3.

In my opinion, despair is the leading cause of new-hire self-destruction.   With a paycheck, you may have garnishments for child support and past bills.  You will also have to feed yourself, find a safe and secure place to live, and most importantly, you may have to find new friends.    Getting overwhelmed with this new lifestyle will certainly get you down.  Particularly because when you graduate, there are no safety groups like Christopher’s Place or counseling sessions.  Probation officers do not seem to fill this essential gap.  The biggest constructive criticism of programs like this one is that there needs to be a continuation of support once you graduate.   Without support, despair creeps in and, there is strong tendency to go back to your old self and just give up.  Don’t give up!

Instead, try to surround yourself with supporting friends and family.  If so inclined, volunteer once-in-a-while to help those who are less fortunate that yourself at this point.   Perhaps you can share or witness your experience, particularly with younger people who are already on the wrong path.   Join a church, or faith based group, or a support group if you can find one that is convenient.  Don’t bottle up your frustration, but be humble and seek out companionship and fellowship.

If you are frustrated with your lack of growth and development, seek self-improvement.   You may need better reading, writing, or computer skills to find a better job.   Don’t just waste your time watching tv, surfing the web, or playing video games when you are not working.  Learn to type, learn Microsoft Office, improve your handwriting.   These are all skills that no one will ask you to do, but are necessary if you want to advance in your job from a manual labor skill to a supervisory or administration position of more responsibility.   Manage your free time for constant self-improvement.

Self-improvement and confronting frustration will keep you from being angry.   Rule # 4 is do not be angry.   Anger on the job is sure to make you isolated and singled-out from your co-workers.   I realize that you have a lot to be angry about in your past, present, and perhaps your future.  Forgive yourself and move on.  I cannot tell you how many other employers are worried about hiring ex-offenders because they fear that there will be violent behavior in their workplace.   Solving conflicts on the streets is not the same we solve conflicts on the job.   Discrimination and sexual harassment are huge concerns at the workforce today.   You need to control yourself, your emotions, and your anger on the job.  Seek help if anger still consumes you – if not, it will eventually bubble over on your job and cause you to lose your employment.

Lastly, Rule # 5 – just as important as all the rest, learn how to save and how to spend.   At Danko Arlington, we have hired individuals who have never had a bank account, or even a job before!  You need to learn how to budget your income so you don’t quickly get in debt.    If your rent is too high, consider roommates, or staying with family.  Perhaps you need to work another part-time job for extra income.   Be careful in making those purchases.  Become frugal.  Save. Save. Save.

In summary, one of the most enjoyable parts of offering second chance opportunities is not only helping society, but seeing the remarkable transition from those who choose to start over, with little to transformation and success.  Success includes being at peace with themselves, getting custody of their kids back, getting an apartment, or car.  These are all huge milestones in completing your transition back into the community.   The ex-offenders that are successful certainly overshadow those who self-destruct.   If one ex-offender is successful, it makes up for the many who fell by the wayside.

Don’t be that one that falls by the wayside!  Employers like Danko Arlington are in great need of reliable workers.  Maryland unemployment is at 3.8% now, that’s less than the 4.1% national average.  Companies are screaming for workers.   Companies will train with skills.  This is a great time to look for work.   Don’t just be a robot or do the minimum, but concentrate on your continued success and improvement.

As this is Thanksgiving week, I want to close with saying thanks to you, Christopher’s Place, and all the other organizations that work with re-entry.  Thanks, because, you and these organizations have inspired me, our company, and so many countless other employers.   If can overcome all the odds and adversity, we too can overcome our daily barriers – many seem so trite in comparison to yours.   Make every day count, and enjoy your renewed freedom – the future is all up to you!

Happy Thanksgiving!



Maryland Commerce Department Visits Danko Arlington

 MD Commerce LogoGill Danko Foundry

On November 16, 2017, Danko Arlington was honored to host Maryland’s Commerce Department, including Secretary R. Michael Gill, Brady A. Walker, J.D., Managing Director & Special Advisor, Steven Pennington, Managing Director, Business and Industry Sector Development, and Todd Sabin, Maryland Manufacturing Program Manager, Office of Strategic Industries and Entrepreneurships.

During the visit, the group learned about Danko Arlington’s near-century of manufacturing patterns, castings, and machined components as well as its vision for the future using additive technologies.

The company is excited to work with Maryland government to revitalize its apprenticeship programs, partner in job training and education, maintain a safe workplace, and increase local and international business.


AFS Metalcaster of the Year: Danko Arlington Plots Its Future

INC. Magazine Features Danko Arlington’s New Technology

Inc Magazine logo


May 1, 2017. Danko Arlington was honored to be one of four Baltimore companies that was featured in INC. Magazine’s Small Business Edition:


Université De Versailles Saint-Quentin-En-Yvelines visits Danko Arlington

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On April 26, 2017, Danko Arlington enjoyed hosting twenty eight French Managers from The LAREQUOI Research Center for Management of the University of Versailles (France) who have traveled to Washington to learn about American business innovations.   Accompanying the European visitors were two staff members from the sponsoring Center for Intercultural Education and Development (CIED) of Georgetown University (Washington DC USA).

Over the years, the company has actively participated with CIED to share its balance between standard business practices, innovation,  and social responsibility.   Danko Arlington is a great example how a well-established  American small business is expanding in both a community and an industry full of barriers.

The exchange of ideas, including differences in government policies, culture, and values are reminders that despite our differences in languages, companies world-wide today, large and small, have common concerns in our global economy.



Mayor Pugh Must Veto the $15 Min Wage

March 16, 2017.  My manufacturing company has survived ninety-seven years in Baltimore. We have outlasted major corporations like the B&O and Bethlehem Steel as well as major regulatory changes and local crime, not to mention wars and major recessions.

Yet our company’s future will be uncertain if the $15 minimum wage set to be passed by City Council next week takes effect. For the sake of all of Baltimore’s small business owners, entry-level jobseekers, and broader economy, I urge Mayor Pugh to veto it.

I am the third-generation owner of Danko Arlington, Inc., a plant that makes custom aluminum parts for the defense industry. Most of our seventy-five employees already make over $15 an hour. We start employees at $11 an hour and teach them the specialized skills to make their labor quickly worth much more. Over one-third of our employees are ex-offenders. We also hire refugees and legal immigrants.

Because we face competition from companies trying to out-bid us in states like Pennsylvania, where the minimum wage is $7.25, we cannot afford to pay our unskilled, starting inexperienced employees at $15 and stay in businesses. Simply put, we cannot afford to pay journeymen wages to unskilled employees.

If this bill becomes law, my business will be forced to dramatically scale back its entry-level employment opportunities – including its ex-offender program — in favor of employees who require less training. In addition, our company is already making contingency plans to increase automation and 3-D printing, which can be maintained and programmed by a few highly skilled engineers. Other employers with fewer options than our company will certainly consider moving to Baltimore County, where the minimum wage will be 49 percent less than the city’s.

Indeed, the minimum wage threat is much greater for city small businesses that have smaller profit margins and lower entry-level wages than my company. Such businesses like restaurants, cafes, and retailers, which are helping gentrify blighted communities, will have to reduce job opportunities or close altogether unless customers are willing to pay dramatically higher prices.

Jay Steinmetz, CEO of Barcoding Inc. on Boston St said that a $15 minimum wage would force him to reduce dozens of entry-level business technology job and training opportunities because the costs associated with the hike would price his business out of competitive, nationwide contracts. And the owner of the call center CMD Outsourcing Solutions has said that a $15 minimum wage would force his business outside the city.

While our business models may be different, all businesses affected by the wage hike have something in common: We help to train the city’s workforce. We teach them the technical and soft skills necessary to quickly earn far more than the minimum wage. Rather than fighting for counterproductive wage mandates, we should be fighting for high-paying middle-class careers – a fight for $50,000 a year incomes. But before people can get a good job, they need a first job. And to protect these first job training opportunities, the entry-level wage must also be protected.

It’s clear that these aren’t job opportunities that Baltimore can afford to lose. City employment has declined by roughly five percent since 2000. Only one in two city residents aged 16 to 24 currently has a job. And in some parts of the city like Sandtown-Winchester, where the 2015 uprising took place, the general unemployment rate is nearly 20 percent, according to the most recent Census Bureau data. Now is not the time to be putting up artificial barriers to employment by outlawing jobs that pay less than $120 a day.

Based on her comments, Mayor Pugh understands these consequences. She has urged caution on a $15 minimum wage, implying that it would create more empty storefronts and threaten the city’s nascent and fragile economic recovery. This perspective may come from the fact that she is a small business owner herself and understands the consequences of higher wage mandates first-hand. She has said that a $15 minimum wage would force her to close her consignment shop an extra day a week to compensate for its associated costs.

For the sake of her business and mine, as well as the city’s entry-level jobseekers and economy as a whole, I ask her to please veto this bill.

John D. Danko,  President


Testimony Against the City $15 Min Wage

March 1, 2017. Good Evening.  My name is John Danko.  I am current volunteering as the co-chair of the Mayor’s Office of Employment Development’s (MOED) Baltimore Workforce Development Board’s Employer Engagement Committee.  Last year, I just finished serving a four-year term on the Maryland Correctional Education Council under Governors O’Malley and Hogan. I am here this evening, however, as the third-generation President of Danko Arlington, Inc.

My business is ninety-seven years old and employs seventy-five people. We make custom aluminum components on East Wabash Avenue.  We compete nationally with other companies located in other states like Pennsylvania, Ohio, and Texas as the low bidder for military spare parts for our Warfighters.  Plain and simple: we cannot afford to start unskilled workers at journeymen’s wages and continue to stay in-business in Baltimore City.

We currently start at $11/hr. and teach niche skills to our employees.   Most of our workers make over $15/hour.   Over one third of our employees are ex-offenders.   We also hire immigrants and refugees.  We receive no-benefit from any program, other that it’s ‘the-right-thing-to-do.’  In many ways, our company is a “poster child” for Baltimore City.  Mayor Pugh is seeking more companies like ours to step-up an offer second chances.  Recently, she has spoken to seek more investment in our Pimlico-Park Heights Community.

Training unskilled applicants, however, comes at great price because most of our low skilled people have a difficult time learning or holding on to a job.   By gradually raising the minimum wage to $15/hr., the city council is effectively incentivizing Baltimore employers not to take the risks to hire second chance citizens.

The Labor Committee has recognized the need for training by amending the bill’s discount for 18-20-year-olds.  However, there are tens of thousands of 28-30, 38-40, 48-50, and even 58-60-year-olds without skills.   There is nothing in this bill, other than interns, that addresses skills, training, advancement, or even apprenticeships.  So, employers will get nothing in return for the phased in higher wages, higher payroll taxes, higher workman’s compensation, and soon-to-be higher city taxes and water bills. As a result, businesses will simply re-hire more skilled and efficient people, downsize, close, or go elsewhere.

This bill is doomed to backfire – hurting those whom this was intended to help.  This is not even taking in to consideration that there will be triple the number of county residents applying for city jobs, thereby reducing the chances of hiring our re-entry workforce even further.  Even small companies, like ours, are already making contingency plans to automate and to replace low skilled people.  This truly sad for all our city employer engagement agencies, including MOED.

Why would the Council want to force employers not to hire?   Isn’t better to start with no skills at Maryland State minimum wages, than have no wages at all in Baltimore?  This bill assumes that there will be the same number of jobs available tomorrow.  This will not be the case if this bill passes.  Baltimore will not attract companies to invest in our city — resulting in stagnation and decline in our fragile neighborhoods.

Instead of opposing our job creators, business and government need to work together to teach our community new skills for life-time careers like promoting MOED’s Youth Works and more on-the-job training.  We need more businesses in our city, especially more minority businesses.  Why isolate Baltimore?  Why separate Baltimore so we cannot compete in a free economy like other regions?  This bill is misguided, and will hurt our residents, especially our re-entry community.  It’s a disaster and certain to fail, setting Baltimore back for generations.   Our City simply cannot afford it.   I urge you to vote “No”.  Thank you.

John D. Danko, President

Can’t Wait to Make America Great Again

January 20, 2017 – Inauguration Day.  My plans are to carve out some time today to see the Vice President and President-elect swear-in and listen to their remarks.   As today is Friday, I am working at the office and planned to go to the company conference room to watch it on the big-screen TV, but too busy to move all my papers. As the program nears, I tried to live-stream the event on my computer, but could not connect. Perhaps too many people doing the same thing…too busy to troubleshoot. As noon nears, too busy to go to my car and listen to the radio. Ah, just forget it, I am just too busy!

The reason why I am so overwhelmed is that I am part of a previous generation that is deeply skilled in manufacturing.  As the last of the baby-boomers, we learned to make things for America, in America, and were trained in apprenticeships, on-the-job training, and plain hard work.   To make matters more complex, I am a third-generation business owner of a ninety-six-year-old manufacturing company with seven smoke stacks and sixty-eight employees trying to get by in a declining marketplace with overdue orders.

Fortunately, my company has been able to stay busy and has been in-business for so long because we have changed with the times: invested in new technology and focused on our niche.  As an example, we use 3-D printing to replace our retired skilled tool and die makers, computerized multi-axis robots to take the place of turning cranks by hand, and digital laser scanning to measure parts instead with micrometers.  Of course, everyone does their all their own paperwork on the computer.

Yes, we Americans are more efficient, accurate, and very fast with our new toys, but sadly however, our newer workforce simply lacks soft skills like showing up, being on time, and working a full week.

Furthermore, many apprenticeships are outdated and date back to the early 1940’s when the Roosevelt administration conceived of these programs.  Our apprenticeship training takes five years or  ten thousand hours — the same time frame which one could earn a Master’s degree. We cannot find young employees who will stick around for one year much less five.

Over the past two decades, our youth have opted to go to college without learning trade skills like ‘Joe the Plumber,’ who by the way, was discussed two elections ago! As a result, our nation has an abundance of well-educated young people that are great in IT and gaming, but unlike their parents, do not know how to make anything.   In addition, our neighboring adolescents who live in our local community are affected by broken families, drugs, and oblivious to the importance of STEM for tomorrows jobs.

Every day, my company is doing a great part in our community by hiring and teaching skills to our neighbors, including ex-offenders, but basically, we are starting from scratch. We also have recruited talented legal immigrants who are well-educated, eager to work, and ready to re-establish their lives in our country.  Still in the end, we ’old-timers’ are left with carrying the heavy load of complex manufacturing and already maxed-out.

With the day drawing to a close, I find myself reflecting and hopeful for the new ideas just presented to our nation.  Yet, I am left bewildered how we are going to build bridges without any welders, produce concrete with new OSHA laws that cut silica exposures in half, and rebuild rusted factories which will require new and expensive equipment run by an engaged, next-generation workforce.

Small businesses will continue to do our little part. No doubt, we Americans will figure this out.  Remember stories and photos of our grandparent’s ‘Greatest Generation’? America IS the greatest country in the world! We are a strong, diverse people, and with the right leadership, will rise to the occasion. Let the dialog finally begin, the goals to be set, and the policies drafted.

For now, I am just too busy to think about it anymore…too much to do!

John D. Danko
Danko Arlington, Inc.



Danko Arlington Presents at NFFS Executive Conference


On October 16, 2016, Danko Arlington was honored to present at the Non-Ferrous Founders’ Society (NFFS) Industry Executive Conference held at the Lowes Ventana Canyon Resort in Tucson, Arizona.

As a NFFS member, Danko Arlington has greatly benefited from the society’s network of resources for metalcasters, so to share with other members its successes with additive manufacturing was a great way to ‘give back.’

All those at the conference keenly understood the challenges facing metalcasters today. The use of additive manufacturing for foundries is just one suggestion for growth in an environment of un-skilled foundry workers, rising labor and health care costs, regulations, the needs for improved quality, lower prices, and shorter lead times.

No doubt, foundries who invest in today’s technology will be in a better position to meet a growing demand for tomorrow’s casting needs.

Danko Arlington Presents at AM4MC


On Wednesday, October 5th, 2016, Danko Arlington was honored to present at the American Foundry Society’s (AFS) first annual Additive Manufacturing Conference for Metal Casting (AM4MC) held at the Sheraton Detroit Novi in Novi, Michigan.

The keynote luncheon topic, entitled “Integration of Additive Manufacturing to Transform a Traditional Metalcasting Company,” explained how Danko Arlington has evolved over the last century including its most recent adaptation of FDM patterns, core boxes, and outsourced 3-D sand printing.

The company is seeking to acquire a 3-D sand printer in the upcoming years. Being able to share ideas and network with AFS and other attendees about recent developments in additive foundry practices was invaluable.


DLA Aviation Visits Danko Arlington

DLA LogoAMC Logo

On Wednesday, September 21st, 2016, Danko Arlington hosted nineteen Defense Logistics Agency Aviation employees who participated in the annual AMC and DLA Aviation Forging and Casting Assistance Team’s (AFCAT) casting seminar and tour.

It’s hard to believe that Danko Arlington, DLA and AMC started this information opportunity ten years ago in 2006.  The seminar and plant tours have been extremely rewarding for all who have attended. This year, the attendees witnessed a large aluminum pour of a military gear box after just seeing the casting “virtually” poured in  solidification software which confirm the cooling rates, thermal gradients,  and absence of micro porosity or shrinkage.   The complex casting is subject to nearly eighty x-rays on each part with no room for defects.

Seeing the efforts behind the metal pouring, including the construction of additive tooling, brings to life each government contract from being just at technical data package (TDP) to a real-life quality product made from scratch used by today’s Warfighter.  Amazing!

Congratulations DLA and AMC on this milestone ten-year anniversary!

Baltimore City Council’s Lose-Lose Proposition

As a native of Baltimore and a third generation President of a ninety-six-year-old manufacturing business with sixty-eight employees located in Park Heights, I am opposed to the $15 min wage bill because it will hurt not only my company’s competitiveness, but hurt our entire city.

Baltimore needs more jobs, training, and skills to prosper. What entrepreneur with visions of making more than $500,000 in sales or hiring more than 25 employees is going to start a business in our city? How can existing, well-established businesses like mine, compete with companies in other states?  How is my company going to survive when we will have to start apprentices at journeymen wages? Won’t our existing journeymen want a raise too? Will our customers pay more for our products made in Baltimore? If not, how will we pay for the increases?

It’s hard to believe that our company, which has endured wars, recessions, depressions, outsourcing, off-shoring, and workforce shortages is being forced into economic hardship by our own city government. It’s also shocking to think that our local businesses will have to pay more for the same unskilled employees who will still have to be trained on-the-job.

At most companies, like mine, employees advance in wages based on attendance, merit, and job performance. This bill disregards those normal business practices, which will make Baltimore undesirable for employers.  As a result, there will be fewer jobs for the next generation – effectively hurting those whom the bill is intended to help as well as those who want to create more jobs in the city.

Overall – a LOSE-LOSE proposition for Baltimore!

John D. Danko, President 7_31_2016



Danko Arlington Hosts Pentagon’s Joint Chiefs J-4 Team

J4 Logistics Team at Danko Arlington IncJoint Chief Logo

On July 19, 2016, Danko Arlington was honored to host the Pentagon’s Joint Chief’s J-4 Additive Manufacturing Team.

The Joint Staff conducts monthly education tours in the summer months known as JED walks.  Danko Arlington’s membership in America Makes – a public-private partnership, as well as its close proximity to Washington,  helped make this tour feasible.

During the visit, the J-4 Team witnessed a wide variety of machined castings made from 3-D printed FDM tooling.  The company makes custom cast components for all five branches of the Armed Forces.  The tour helped the warfighters understand how Danko Arlington’s additive edge enables the company to  make complex and difficult-to-purchase cast components.

No doubt, the team returned to Washington and advised the Chairman of the Joint Chiefs that Danko Arlington’s increased capabilities and agility is an inspiring model for the entire DOD supply chain.

Danko Arlington Presents at HCC

Howard Community College logo

On Wednesday, April 20th, 2016, Danko Arlington was honored to present a lecture entitled, “Transforming the Sand Foundry with Additive Manufacturing” to Howard Community College in nearby Columbia, Maryland.

Coordinating the visit were David M. Hinton Associate Professor, Computer Aided Design, and Mark Edelen, Assistant Professor and Chair, Engineering & Technology Department.

The audience was composed of both students and faculty (full time and part-time) from the Science, Engineering, & Technology Division.   The event was a great opportunity for the attendees to see how rapid technologies are shaping a local, well-established manufacturer into the future.



Danko Arlington Hosts UMBC Racing

UMBC Racing LogoUMBC Baja 2014

On Wednesday, March 9th  and Monday, April 11th, Danko Arlington was honored to host members of the University of Maryland, Baltimore County’s Baja Racing Team.

According to Paul Darling, the UMBC Baja Undergrad Team Captain, “we were interested in having several parts that would be more efficient to cast compared to our usual methods. We also have a few things that would be a lot easier to work with if they were 3D printed.”

During the visit, the mechanical engineering students were able to learn about 3-D printing and foundry practice.  Over the following days, Danko Arlington assisted the young engineers to improve their CAD designs to make better castings.  The company eventually provided the team 3-D printed plastic pattern tooling with the condition that they return to the foundry, make the molds, and partake in the casting process.

As a result of this special visit, the team now has a greater appreciation of the art of metal casting. In addition, they now know how foundries use rapid technology in the race to produce prototypes for engineers on the go!




Danko Arlington Acquires 20,000 sq ft.

4715 E Wabash Ave Baltimore_MD

On March 23rd, 2016, Danko Arlington acquired a twenty thousand square foot facility adjacent to its current manufacturing operation in Northwest Baltimore.

In reality, the company re-acquired the property!

In 1953, Joseph O. Danko, Sr. constructed the building as a machine shop for a product line of corrugated printer-slotter machinery under the name of Greenwood Engineering.  In 1959, the Langston Company purchased Greenwood and moved the business to New Jersey.  The building exchanged hands for lite manufacturing and warehouse space for the next fifty-seven years , until it returned to its Danko heritage in 2016.

The facility is especially designed for fabrication and was packed with robust machine tools during the Greenwood times.  Danko Arlington intends to return to those good old days, like some sixty-three years ago, when its castings were used in a family owned product line —  poised for growth for the next generation.

Greenwood Engineering 4715 E Wabash_1Greenwood Engineering 4715 E Wabash_2

UVSQ Visits Danko Arlington

USVQ logo

On March 17th, 2016, instead of celebrating green for Saint Patrick’s Day, Danko Arlington was celebrating the tricolors of red, white, and blue (the colors of France!)  when it hosted a group of twenty-eight executive MBA students from the University of Versailles (Saint-Quentin-en-Yvelines Université).

The tour is a result of a special relationship the company has fostered with The Gateway to Georgetown Programs, Georgetown University, and Center for Intercultural Education and Development (CIED).

As we now work in tighter world economy, the exchange is a great way for Danko Arlington to highlight how global forces can influence even a local manufacturing setting in Northwest Baltimore.  Metal, commodities, energy, and interest rates are just a few examples of markets monitored daily at the company.   Even small businesses across the globe are concerned with cyber security and intellectual property in this digital age.

As always, the tours bring valuable understanding to the challenges ahead in an ever-shrinking world market — now just a click away.

Danko Arlington Hosts Baltimore Robotics

BRC Logo

On March 15th, 2016, Danko Arlington hosted a group of students from the Baltimore Robotics League.

The League assists local kids to design and compete their home-made robots for local and national competitions.  Coincidentally, the League is based out of an renovated building that was once part of the B&O Railroad’s Mount Clare Shops which was one of Danko Arlington’s first customers in the 1920’s!

According to Ed Mullin, the Executive Director of the Baltimore Robotics Center, “the kids were really jazzed about the technology they saw at Danko Arlington, especially the 3D printers.”

Tapping into the younger generation is crucial for American manufacturing to grow and prosper.  Many of Danko Arlington’s employees started their apprenticeships at the age of eighteen.   Once a young person is hooked, entry jobs can easily result in life-long careers, especially in niche manufacturing such as metal casting.

The company looks forward to hosting more robotics students, especially during holidays and the summer months.   The League is a great place to foster relationships for the next-generation Baltimore manufacturers.

How ironic that one hundred year old railroad and foundry facilities in Baltimore have become living classrooms for aspiring engineers learning about robotics – the future of advanced manufacturing!


After ‘providential’ connection, Baltimore company makes replicas of Seton house key

By Lindsay Powers, Frederick News-Post; lpowers@newspost.com; Mar 11, 2016

John Danko, President of Danko Arlington, center, shows the key molds to onlookers from the National Shrine of Elizabeth Ann Seton. From the left, Sister Dinah White, Sister Lawrence Marie Callaghan, Sebastian Arbona of Danko Arlington, and Ray Alcaraz, Director of Development and Stewardship.

John Danko, President of Danko Arlington, center, shows the key molds to onlookers from the National Shrine of Elizabeth Ann Seton. From the left, Sister Dinah White, Sister Lawrence Marie Callaghan, Sebastian Arbona of Danko Arlington, and Ray Alcaraz, Director of Development and Stewardship.











For John Danko, the call last year from the National Shrine of St. Elizabeth Ann Seton was both out of the blue and providential.

Staff at the shrine were looking for someone to make a copy of an original iron key that Seton had used for her Stone House in Emmitsburg, which is on the grounds of the National Shrine. Though the manufacturer didn’t know it at the time, the key would be given away soon by President Barack Obama to someone important — Pope Francis, to be precise. Danko, president of Danko Arlington, said his manufacturing company in Baltimore took on the project, creating a virtual replica of the historic key, with every scratch and dimple recorded. From that digital copy, a polycarbonate plastic copy was created using a 3-D printer.

On March 1, Danko Arlington went a step further. In a final stage of a complex process, the company used sand molds to create 30 silicon bronze copies of Seton’s key. Those keys, free of charge to the Shrine, will be placed in exhibits and used for gifts.  Danko is a third-generation foundryman, or someone who casts metals. His company’s work includes custom castings and often involves creating parts for the military or Fortune 500 companies.  The request was of particular interest to Danko because of his and his family’s connection to it and the area’s Catholic community. Danko attended seminary at Mount St. Mary’s University nearby.

“We know the Shrine very well as a family,” he said.  Those at the Shrine may not have known about his connection, but he thinks God “likes to pick good suppliers that can perform under pressure.”  Rob Judge, executive director at the Shrine, said when the U.S. Department of State confirmed with the Shrine that it wanted to use the key as a gift for the pope, staff at the Shrine had about a day to see if it could make a copy.

As Judge put it, Danko bumped into their lives. Judge’s assistant found Danko Arlington through an Internet search and the company’s assistance — within a roughly 24-hour period — allowed the organization to have a copy that could be replicated.  It was also a real blessing to have an exact copy of the key presented to the pope, Judge said. A second, slightly different original key to the house, is also at the Shrine.

The key that was given away “has a lot of rich symbolism,” he said, as both an intimate and an ordinary object. “That’s the kind of life she led, a very ordinary life in one way,” Judge said. But the way she lived her life became something extraordinary, particularly in how she cared for poor children and followed God’s will, he added.

Among her accomplishments, Seton founded the Sisters of Charity of St. Joseph’s and started the St. Joseph’s Academy and Free School for girls, according to the Shrine’s website. In 1975, she became the first person born in the U.S. to be canonized as a saint.

Sister Dinah White said it was inspiring to watch the metal being poured into the molds to create the keys, a method with thousands of years of history. White is a member of the Daughters of Charity and serves as mission leader for the Emmitsburg campus that includes the Shrine.

She and others from the Shrine were given a tour of the company March 1 that included some history of Danko’s family’s work and some of the steps taken to make the replicas possible, including the 3-D printer. “It was just totally remarkable,” she said. “And then to watch the men pour the keys, I was so in awe!” White, who moved to Emmitsburg about a year ago, said the keys will become meaningful gifts that can help people recognize the good from God in their lives.

“To see anything that gives us the opportunity to share that heritage with others and hopefully give them confirmation in what their doing is a blessed honor,” she said.
White said she was also impressed with Danko’s “Christian spirit that just shone through.”
“He was just very gracious to show us the whole process and spend time with us,” Judge added.

Follow Lindsay Powers on Twitter: @linds_powers.


Danko Arlington Participates in BDC Workforce Program

Baltimore Developement Corp Logo

On March 8, 2016, Danko Arlington was excited to take part in a special Baltimore Development Corporation seminar held at the Baltimore Hilton entitled, Workforce of the Future: Resources to find talented & motivated employees”

The program featured presentations from Bill Cole, President & CEO, Baltimore Development Corporation (BDC), Mayor Stephanie Rawlings-Blake, Michael Galiazzo, Regional Manufacturing Institute, Secretary Kelly Schulz, Maryland Department of Labor, Licensing and Regulation, and Mary Sloat, Assistant Director, Mayor’s Office of Employment Development (MOED).

The event consisted of speakers and panelists to discuss strategies to develop, recruit, and retain employees.  In addition, attendees learned how an industrial employer can connect to the training pipeline in Baltimore.  The City has outstanding resources to local business!

Danko Arlington’s interest in STEM, local schools, and working with local and city organizations such as MOED were shared as long term solutions for future skilled workers. No doubt, a shortage of talent is one of the greatest concerns of today’s manufacturers.

Danko Arlington Presents at 2015 DMC/DMSMS


DMS logo1

On November 30th and December 2nd, John Danko was honored to participate on two additive manufacturing panels at Diminishing Manufacturing Sources and Material Shortages and the Defense Manufacturing Conferences (DMC) held at the Hyatt Regency Phoenix and Phoenix Convention Centers.  The theme of this year’s convention was “The Future is Now… Creating Innovation Paths Towards Game Changing Results.”

During the conference, Danko Arlington’s efforts in adopting additive manufacturing to replace the obsolete trade of patternmaking for DOD castings were highlighted as a model for the contracting industry. In addition, special emphasis on improved metallurgy and state-of-the-art foundry practices were discussed as options to lesser known and expensive 3-D metal printing.

Obviously, innovations in additive manufacturing has caught the attention of the Warfighter who is currently seeking to find a balance between new methods of making things, product reliability, cost, and safety. Through information exchanges such as the DMC/DMSMS conferences, government and industry are learning the pros and cons of adopting additive for continuous improvement of our national security.

John Danko Awarded Northrop Grumman Scholarship


NGES LogoTuck School Logo

From November 15th-20th, 2015, John Danko was honored to attend the Tuck Business School at Dartmouth College as the 2015 Northrop Grumman Electronic Systems’ Minority Business Scholar. Danko Arlington is a certified SBA HUBZone concern and a supplier of aluminum castings to NGES.

The one week executive retreat entitled “How to Build a High Profile Minority Business” was held on campus in Hanover, NH, and mentored by world renowned Tuck faculty. In attendance were over sixty business minority leaders from around the country aspiring to sharpen skills in finance, management, and marketing.

The intensive program enabled the group to refresh the basics of a business degree, reflect on how to better their own organizations, as well as network with others with similar responsibilities in the challenges in growing minority businesses.

Northrop Grumman’s innovative sponsorship of the Tuck program underscores its commitment to both diversity and education as our minorities will soon become the majority in future American supply chains.

Danko Arlington Presents At Northrop Grumman ESSS AM Fair

Northrop Grumman Logo

On October 14-15, 2015, Danko Arlington was honored to be included in Northrop Grumman Electronic Systems’ First Additive Manufacturing Fair held at its Linthicum, Maryland facility.

During the event, Danko Arlington shared its decades of history as an aluminum sand casting vendor for current ESSS and former Westinghouse programs. It’s hard to believe that back then, skilled pattern makers made foundry patterns out of pine and mahogany by entirely hand.

Today, with the retirement of that “greatest generation,” Danko Arlington is pioneering new methods in 3-D printing accurate and reliable foundry tooling, as well as printing some non-critical aerospace metal parts in lightweight thermoplastic. As a result, the company is expanding its additive capabilities – manufacturing components which were once inconceivable with traditional casting and CNC methods.

Likewise, additive manufacturing also is providing Northrop Grumman new innovation to create superior products at lower costs. Overall, the Tech Fair provided an exciting “win-win” atmosphere for engineers and vendors – underscoring The Value of Performance of Northrop Grumman.

Danko Arlington Copies Papal Key


mother seton


2014 Pastoral Visit of Pope Francis to Korea Closing Mass for Asian Youth Day August 17, 2014 Haemi Castle, Seosan-si, Chungcheongnam-do Ministry of Culture, Sports and Tourism Korean Culture and Information Service Korea.net (www.korea.net) Official Photographer : Jeon Han This official Republic of Korea photograph is being made available only for publication by news organizations and/or for personal printing by the subject(s) of the photograph. The photograph may not be manipulated in any way. Also, it may not be used in any type of commercial, advertisement, product or promotion that in any way suggests approval or endorsement from the government of the Republic of Korea. If you require a photograph without a watermark, please contact us via Flickr e-mail. --------------------------------------------------------------- 교황 프란치스코 방한 제6회 아시아 청년대회 폐막미사 2014-08-17 충청남도 서산시 해미읍성 문화체육관광부 해외문화홍보원 코리아넷 전한

Papal Flag

Key2 (2)

Did you ever wonder if Jesus made copies of the keys to heaven before giving them to Saint Peter? After all, what would happen if Peter, Jesus’ successor and the first Pope, accidentally got locked out?

Certainty, this must have crossed National Seton Shrine Director Rob Judge’s mind the day before he was to hand over to President Obama the original key of the home of Elizabeth Anne Seton –America’s first native born Saint.  President Obama presented this treasured artifact to Pope Francis upon his arrival at the White House on September 23, 2015, as an official United States gift to the Vatican.

Mr. Judge’s dilemma was how to make a copy of two hundred year old custom skeleton key in less than twenty four hours.

Quite unexpectedly and out-the-blue, Mr. Judge’s office contacted Danko Arlington – a local Baltimore foundry with laser scanning, reverse engineering, and 3-D printing capabilities. Unbeknown to the Shrine, generations of the Danko family have a long standing fondness of Mother Seton, The National Shrine Grotto of our Lady of Lourdes, and have studied at Mount Saint Mary’s University & Seminary in Emmitsburg, MD.

Using reverse engineering laser scanning software and 3-D printing, Danko Arlington was able to make a digital “virtual” key and exact 3-D copy in a matter of minutes with the project completed, including 100 miles round trip transportation, twenty hours ahead of the deadline!

Not only is this story a  testament of Providence, but of the accurate and reliable tools of digital fabrication available to manufactures today. Thanks to rapid technology, the Seton Shrine not only has an exact replica of an historic artifact, but does not have to call Pope Francis if they ever get accidentally locked out.  Thank God!

Danko Arlington Provides Helping Hands

Danko Arlington 3_D Hande_nable logo2

On September 9th, 2015, Danko Arlington delivered sixteen hands sets to Enabling the Future – a unique charity comprised of volunteers dedicated to helping  people with hand abnormalities.

Using its state-of-the-art 3-D printing technology, the company was able to effortlessly download and create the custom polycarbonate plastic parts for e-NABLE’s latest “Rapter” design.  After the printing process, the hand pieces are cleaned, buffed, and assembled with cables to allow wrist motion to closed the fingers.

For those who are born with hand disorders such as Poland Syndrome, this invention is a life changer.   Danko Arlington is proud to be one of the thousands of Enabling the Future Volunteers making a difference in children and adults around the globe.

Danko Arlington Presents at DLA Columbus

AMC AM for Castings Banner

                                                                                                                                                                                On September 1st, Danko Arlington was honored to be included in the first Additive Manufacturing for Castings Seminar at the Defense Logistics Agency’s Land and Maritime Campus in Columbus, Ohio.

The American Metal Casting Consortium (AMC) coordinated the event with DLA’s Casting and Forging Team to discuss today’s uses, challenges, and benefits of additive manufacturing. With this technology, contractors like Danko Arlington are able to supply more accurate and reliable components at lower costs to the tax payer.

Overall, the seminar was a huge success and laid the groundwork for the future collaborations between industry, government purchasing, and the Warfighter for an all-around win-win for the USA.

Danko Arlington Expands in Multi Axis Machining

Danko Arlington is pleased to announce its investment in a state-of-the-art CNC machining center manufactured by Okuma Corporation, Japan.

The Okuma Multus U4000 robotic machine enables simultaneous high speed turning and milling capabilities in eleven axes within an envelope of 25.59” Diameter x 78.74” long.   The new acquisition provides Danko Arlington with the possibility to turn, mill, drill, and tap its aluminum and bronze sand castings in just one setup.

In addition to reducing multiple setups, fixtures, and operator involvement, the machine will also enable the company to offer complex 5-axis hogouts from ferrous or non-ferrous billet as an option to its sand cast material.  In fact, the decline of the foundry industry over the past two decades, as well as the advances in cutting tool technology have prompted today’s engineers to design whittled-out components out of solid blocks instead of using traditional casting processes.

The effect of this next-generation technology, also known as a “machine shop in a box,” will certainly decrease the company’s lead times while increase accuracy, reliability, and productivity for castings or hogouts.  Once again, automation comes to the rescue of America’s manufactures — not only surpassing the skills-gap in the declining trade of machining, but now enabling even small business to compete in a global economy.

August 2015


The Sky is the Limit for 3-D Printing at Danko Arlington


Credits: Contributed Photo / Near Space Corporation

3-D Printed TVA Reentry Capsule

3-D Printed TVA Reentry Capsule

Credits: Contributed Photo / Near Space Corporation

 What’s faster than 3-D printing at Danko Arlington?  How about a 3-D printed capsule that traveled to an altitude of 101,250 feet then dropped – reaching a speed of 370 mph during its decent!

On June 21st, 2015, a custom capsule printed at Danko Arlington and designed by Terminal Velocity Aerospace (TVA) of Atlanta, GA, was launched from a high altitude balloon in Tillamook, Oregon. During the over nineteen mile plunge, scientists monitored the effects of the reentry forces on capsule’s contents including electronics, communication systems, and a stem cell sample.

Funded by NASA’s Flight Opportunities Program based in the Armstrong Flight Research Center in Edwards, California, the tests already show great promise for the future of astronaut mail.   Soon, scientists will be able to use inexpensive capsules to return experiments from outer space even faster than overnight shipping!

ABC Honors Danko Arlington

One June 13th, 2015, Danko Arlington was recognized by the Associated Black Charities of Maryland (ABC) for the 2015 Community Investor Award at the 30th Anniversary Gala Celebration held at Martins West in Baltimore.  Over nine hundred people were in attendance.

The Community Investor Award is bestowed on those organizations which support increasing the African American middle class which is the core goal of ABC’s  “More in the Middle” initiative (MitM).

ABC’s mission is to create measurably healthier and more prosperous communities through responsible leadership and philanthropic investment.

Danko Arlington Roadmaps the Future

On May 12th-13th, 2015, Danko Arlington was honored to participate in a special Metalcasting Roadmapping Workshop held at the O’Hare Hyatt Regency Hotel in Rosemont, Illinois.

The meeting was hosted by The American Metal Casting Constorium (AMC) and was sponsored by the National Institute of Standards Technology (NIST). During the conference, a small group of industry experts, technical associations, and research universities joined together to discuss and prioritize short and long term goals necessary for the viability of American metal casters.

Break-out sessions for special areas of interest included design, process, workforce, and awareness.  Overcoming the obstacle known as “tribal knowledge” was common concern, particularly as key people continue to retire and foundries close.

Danko Arlington was eager to share how employer engagement and the pioneering use of the additive manufacturing can revive a well-established foundry business into next generation manufacturing.

The survival of American metal casting is crucial to both our economy and defense.  The loss of casting suppliers of military components is becoming a serious national security crisis.   The collaboration of industry and government is therefore necessary to establish a mutual consensus how foundries can grow and compete in an ever-competitive world economy.

WYPR Hosts Danko Arlington

On Monday afternoon, May 11, 2015, Danko Arlington was featured on “Midday” on WYPR 88.1 FM– Baltimore’s public radio station.  Midday is WYPR’s daily public affairs program and is hosted by long time Baltimore Sun columnist Dan Rodricks.  The featured topic that day was the state of manufacturing in Maryland, including new skills and job creation.

With the recent wake of city unrest after the death of Freddie Grey, special focus was made on how manufacturing could address long-term poverty and relatively high unemployment in inner-city Baltimore and other cities.

Danko Arlington’s success with employer engagement, hiring from faith based groups, and collaboration with the Mayor’s Office of Employment Development was able to provide listeners with hope for positive change in Northwest Baltimore.

Danko Arlington Presents at 2015 AMUG

On April 22, 2015, Danko Arlington presented “The Use of Additive Manufacturing in the Sand Foundry” at the 2015 Additive Manufacturing Users Group held at the Hyatt Regency Riverfront Hotel in Jacksonville, FL.

The recent advances in 3-D metal printing were noticeable in this year’s conference.  Soon  manufacturers will be able to procure and afford additive metal objects in compliance with accepted commercial and military standards.

These new technologies may eventually replace the millennia-old art of metal casting.   If Danko Arlington is to remain a valuable casting supplier in the next-generation marketplace, 3-D metal printing is the logical next step in our company’s future as well.

In the interim, Danko Arlington will continue to bridge the gap by educating today’s engineers about the century-proven sand casting process with the use of 3-D printed foundry tooling, molds, state-of-the-art CAD design, casting simulation, and reverse engineering.

Maryand Recognizes Two Danko Arlington Long-Term Employees

GoodrichSherrill Photo2







On March 26th, 2015,  two of Danko Arlington’s longest tenured employees were recognized at the 25th Regional Manufacturing Institute (RMI) Anniversary — Decades of Dedication Gala held at Martins West in Baltimore.

Howard Goodrich was celebrated with 58 years of service — the longest serving employee at the event.  Mr. Goodrich began his employment in 1955 immediately after graduation from high school.  He entered the company’s five year, ten thousand hour apprenticeship program for patternmaking, and eventually became the Pattern Shop Superintendent until he retired in 2013. He recently began working again part time.

Howard has unique woodworking skills that combine mold making, blueprint reading, machining, art, geometry, and true craftsmanship.  During his lifetime, he constructed thousands of patterns, including complex dredge pump patterns, scaled wooden hulls for ships and subs from eighteen foot mylar drawings for water tank testing at the neighboring Naval Surface Warfare Center.   His most famous model was of the Hugh’s Glomar Explorer — a secret ship used by the CIA to recover a sunken Soviet submarine in the early 1970’s which was the largest covert CIA operation in history.   Today, Howard’s traditional patternmaking skills have become obsolete and are now replaced by CAD and 3-D printing technologies.

Mike Sherrill was also honored with thirty seven years of continuous employment at the company.  His duties include belt sanding, grinding, and sand blasting of aluminum and bronze cast castings for commercial and defense applications, including most of today’s ships, tanks, and military aircraft.  Danko Arlington is proud of Mike’s work and tenure.  He is a true role model in our industry who will certainly inspire young people today to find not just a job — but a career.

Danko Arlington is grateful for the many years of loyal and dedicated service from these special co-workers.  Both men were presented with citations from the newly elected Governor Hogan Administration for their outstanding achievement in Maryland manufacturing.

Danko Arlington hosts the Barrie School

On March 24, 2015, Danko Arlington hosted students from the Barrie School—a private K-12 school located in Silver Spring, Maryland.

The field trip nicely complemented the student’s recent studies in rapid prototyping and related technologies.   Along with Mr. Tommie Hata, the school’s Technology Integration Specialist, the high school students were able to see the same technology as their recently acquired Makerbot 3D printer apply to a well-established industry.

The students now have a greater understanding of the unlimited creativity that additive manufacturing brings to making things – something that companies like Danko Arlington are keenly interested in sharing with tomorrow’s workforce.

Danko Arlington Participates in the ABC’s Volunteer Career Mentoring Program

Danko Arlington is honored to participate in the Associated Black Charities’ Volunteer Career Mentoring Program.

The program is designed to assist low wage African American workers who desire to advance in a career but lack the necessary skills to reach their goals.  As a mentor, Danko Arlington will help teach the essential soft skills required for successful, long-term, and self-fulfilling employment.

In addition, the company will assist in job training and counseling to ensure that participants can pursue their dreams in today’s expanding and exciting workforce.

February 2015

Danko Arlington Participates in YO! Baltimore

Danko Arlington is very pleased to participate in YO! Baltimore – a unique program operated by the Baltimore City Mayor’s Office of Employment Development for residents between the ages of 16-24.

The program offers local youth the opportunity to learn new skills and workforce opportunities.   Danko Arlington will introduce participants to basic foundry skills such as molding, core making, and nonferrous metallurgy.

For centuries, skilled trades, including the are of metal casting, were taught at the workplace to young people who were known as apprentices.  It was only after many years of on-the-job training, that an apprentice would become a skilled worker, journeyman, or member of a guild.   Many of the company’s current staff started at the age of eighteen as apprentices themselves.  Danko Arlington’s workforce is eager and excited to pass-on years of knowledge and experience to the next generation!

February 2015


Danko Arlington Participates in DLLR OJT Training

Danko Arlington has become one of many Maryland State businesses, and the first company in Baltimore City to participate in the Department of Labor, Licensing, and Regulation’s On the Job Training Program (OJT).

The program is supported by the National Emergency grant awarded by the U.S. Department of Labor’s Employment and Training Administration and allows up to 90% reimbursement of on-the-job training for the first six months of employment to pre-screened and qualified workers.

Danko Arlington epitomizes the many obstacles facing today’s US manufacturers.   The company relies on skilled labor to produce its custom components.  In fact, metal ingot is the only direct material this business procures — with indirect materials and labor making up the balance of each product.   The program is therefore a great benefit to help American manufacturers like Danko Arlington who rely on new trainees to expand and compete in a global economy.

January 2015


Danko Arlington Joins American Makes

On January 22, 2015, Danko Arlington joined the National Additive Manufacturing Innovation Institute also known as America Makes.

This public-private effort will accelerate U.S. industry utilization of printed tooling to enable greater supply chain efficiencies and further posture companies to be more profitable, globally competitive, and sustain manufacturing jobs.

Danko Arlington is now one of a handful of foundry organizations who are working to establish a network of printing services, develop and educate future workers, and enable knowledgebase management

Danko Arlington Presents at Chesapeake Chapter AFS

On Thursday, January 15th, 2015, John Danko presented “The Use of Additive Manufacturing in Sand Casting and Patternmaking” at the American Foundry Society’s Chesapeake Chapter (AFS) winter meeting held at the Bay City Restaurant in Hanover, PA.

During the event, local members learned how Danko Arlington has invested in 3-D printing technology to replace the construction of traditionally hand-made patterns.  Also discussed, were the accuracies, efficiencies, and benefits of plastic printed tooling over CNC machined ren-shape or metal tooling.

Overall the chapter benefited by hearing how additive manufacturing can overcome the lack of tool and die making skills today that have been so essential for the industry.  Also discussed were the new type of tech-jobs that Danko Arlington has created — new skills required for 3-D printing and CAD designers, new positions for lower skilled workers, including molders, coremakers, and grinders, as well as a glimpse of the metal casting in the future.

Needless to say,all who attended were in agreement that in order to survive, American foundries need to adapt, grow, and compete in an ever increasing digital world.

Danko Arlington joins BWIB

On December 9th, 2014, Danko Arlington became the newest member of the Baltimore Workforce Investment Board (BWIB).

BWIB’s mission is comprised of area political and business leaders who are committed to grow a world class workforce development system that drives and supports the local economy.

As a Baltimore manufacturer expanding with new technology, Danko Arlington looks forward to sharing with the Board how innovative technologies such as 3-D printing create new jobs, training, and advancement opportunities to local city residents.


Danko Arlington Presents to SBA Administrator Contreras-Sweet

John Danko exhibits a 3-D printed pattern to SBA Adminstrator Contreras-Sweet and Howard County Exectutive Allan Kittleman

John Danko exhibits a 3-D printed pattern to SBA Adminstrator Contreras-Sweet and Howard County Exectutive Allan Kittleman




On December 8th, 2014, Danko Arlington was honored to present to Maria Contreras-Sweet, the head of the Small Business Administration and member of President Obama’s cabinet.

Sponsored by the Maryland Center for Entrepreneurship and 3D Maryland, Mrs. Contreras-Sweet joined newly elected Howard County Executive Alan Kittleman and the Howard County Council to learn more about 3D printing/additive manufacturing technologies.

During the event, Danko Arlington shared how additive technologies has helped to expand its SBA HUBZone Certified Small Business  win new business, create new jobs, and become a leader in the American foundry industry.

Trois-D à Danko Arlington






On November 20th, 2014, Danko Arlington was honored to host a group of French business students from the L’Institut Supérieur de Management de l’Université de Versailles Saint-Quentin-en-Yvelines, France to showcase how 3-D printing is advancing American manufacturing.

The students were participating in nearby Georgetown University’s Center for Intercultural Education and Development (CIED) in collaboration with UVSQ.  Over afternoon coffee and pumpkin pie, the visiting students learned how traditional hand-crafted skills at Danko Arlington have been replaced with additive manufacturing – technology that now enables even small manufactures to compete on a global scale.

No doubt, the students will return to France with a better understanding how 3-D printing is changing our world economy — one layer at a time.

Danko Arlington Presents at LVFA

On November 6th, 2014, Danko Arlington presented a special seminar for the Lehigh Valley Foundrymen’s Association (LVFA) held at the Barnhouse Village Restaurant in Bath, PA.

John Danko, who is an alumnus of neighboring Lafayette College in Easton, PA, spoke to nearly sixty local attendees on how additive manufacturing has radically changed Danko Arlington’s pattern and foundry operation.    In addition, a variety of 3-D printed patterns, core boxes, molds, and fixtures were on display to reinforce the many uses of rapid technology for today’s metal casters.

Under current chairmanship of Tom Druckenmiller, President of Bridesburg Foundry, the Lehigh Valley Foundrymen’s Association is a non-profit corporation that was formed 64 years ago to advance the knowledge of the local foundry industry at the first line management level.

Danko Arlington Presents at MEDA

On October 26th, 2014, Danko Arlington presented at the Maryland Economic Development Association Fall Conference “Advancing Manufacturing in Maryland” held at the Rocky Gap Resort in Cumberland, MD.

During a panel discussion moderated by Jan Baum of 3D Maryland, State officials, educators, and local manufacturers learned how 3-D printing and additive manufacturing technologies are being used at Danko Arlington to create new jobs and business opportunities in Maryland.


Danko Arlington Hosts James River LOA and DSCR

On October 22nd, 2014, Danko Arlington was honored to host the James River Chapter of the Logistics Officers Association (LOA), personnel from the Defense Supply Center Richmond (DSCR), and staff of the American Casting Consortium (AMC).

During the plant tour, the group learned about Danko Arlington’s expanding use of additive manufacturing in its traditional foundry and machine shop businesses.  The participants saw how state-of-the-art 3-D printed patterns, core boxes, jigs, and fixtures are being used in the entire company operation.

Overall the visitors achieved a greater understanding how Danko Arlington is gaining market share in complex, high-quality custom-cast components at the lowest price for today’s budget conscious Warfighter.

Danko Arlington Featured in Baltimore’s Manufacturing Forum






Danko Arlington was honored to be featured in the Baltimore Development Corporation’s first annual Manufacturing Forum held on October 7th, 2014 at the Baltimore Hilton.

The program provided opportunities for industry, city government, and support organizations to network, share ideas, and discuss the common goal of growing the city’s manufacturing sector.

During the event’s Innovation Panel, John Danko presented the company’s near century of local history, present day workforce challenges, and how 3-D printing will help to create more jobs in a now niche casting market.

Danko Arlington Recognized by the City of Baltimore


Photo courtesy of Glenwood Jackson Photography.

Photo courtesy of Glenwood Jackson Photography.

On August 19th, 2014, Danko Arlington was honored to receive the Baltimore Workforce Investment Board’s (BWIB) Award for Workforce Development Excellence.

Over two hundred and fifty people were in attendance at the award ceremony which was held in conjunction with the Baltimore City Chamber of Commerce’s “Annual Breakfast with the Mayor” at the Forest Park Golf Course’s Rawlings Fulton Club House in Northwest Baltimore.

John Danko and Foundry Superintendent Dan Lightner accepted the award from Mayor Stephanie Rawlings-Blake for the company’s efforts in employer engagement, on the job training, and job creation through innovative 3-D printing technology.

Danko Arlington Presents to Maryland Elected Officials

Courtney Watson, Senator Barbara Mikuski, Jan Baum, and John Danko discuss 3-D Printing. Photo Courtesy of Scott Kramer, Howard County

Courtney Watson, Senator Barbara Mikuski, Jan Baum, and John Danko discuss 3-D Printing.
Photo Courtesy of Scott Kramer, Howard County

On Monday, July 21st, 2014, Danko Arlington was honored to showcase its innovative of use 3-D printing technology to U.S. Senator Barbara A. Mikulski (D-Md.) and Howard County Council Vice-Chairperson Courtney Watson.   The special event was held at the Maryland Center for Entrepreneurship in Columbia, Maryland.

Danko Arlington was one of several successful Maryland companies who presented how additive manufacturing has increased its business and created jobs.  Also discussed were the challenges to replace older manufacturing trades with new skills and how MCE’s 3DMaryland, under the Direction of Jan Baum, is preparing the next generation of  manufacturers.

Danko Arlington Sponsors JHU Baja 2014