Ingersoll and 425 Manufacturing bring the Dallas Cowboys’ Iconic Red Kettle to life for a Good Cause
ROCKFORD, Illinois. — Ingersoll Machine Tools is proud to announce its collaboration with 425 Manufacturing in support of The Salvation Army by helping recreate the Dallas Cowboys’ iconic Red Kettle for this year’s holiday fundraising campaign.
A Partnership for a Purpose
The initiative was spearheaded by Micheal Thomason, president of 425 Manufacturing, who invited Ingersoll to join the project and contribute with its advanced manufacturing expertise to this important community endeavor. As part of the collaboration, Ingersoll offered its additive manufacturing capabilities to 3D-print the oversized kettle using carbon fiber and a heavy-duty polymer. The structure weighs more than 225 pounds, stands nearly 4 feet tall, and spans almost 6 feet in width. The crafting required over 12 hours of continuous production, followed by a meticulous finishing process, after which 425 Manufacturing applied the bright red coating to achieve the kettle’s signature appearance.
Technology Highlights
- Advanced Multi-Axis Additive Manufacturing: Ingersoll leveraged its multi-axis 3D printing capabilities, enabling the production of complex curved geometries and larger overhangs compared to traditional additive systems. The tilting extruder allows seamless deposition across the kettle's rounded surfaces.
- AI-Driven Slicing: The part was sliced using AiBuild’s AI-powered software, optimizing toolpaths, material flow, and overall print integrity, key factors in large-scale additive manufacturing.
- High-Performance Materials: The kettle was printed using SABIC AC004XXAR1 ABS+CF, a carbon-fiber-reinforced polymer selected for its strength, dimensional stability, and durability: ideal for a large-format public installation.
At Ingersoll, we are honored to support initiatives that strengthen our community
, said Jason Melcher, Vice President and Sales Director of Composite and Additive Technology at Ingersoll Machine Tools. This project allowed us to put our technology and engineering capabilities at the service of a meaningful cause. Working alongside local partners and contributing to their efforts and initiative on something that positively impacts people’s lives is really important, and what we deeply value.
Technology in Service of the Community
The new Red Kettle made its debut at the Stroll on State celebration in Rockford on Saturday, November 29th, 2025. The installation represents a powerful example of how local businesses and community organizations can unite to support charitable programs and inspire new avenues for holiday giving.
Source:https://www.mystateline.com/news/rockford-salvation-army-local-businesses-recreate-dallas-cowboys-red-kettle/