Ohio State holds bootcamp to help train the next generation of defense manufacturers

Original source: 10TV (WBNS-TV)

The Ohio State University recently hosted a METAL bootcamp to train the next generation of skilled workers for the U.S. defense manufacturing sector. Sponsored by the Department of Defense and led by IACMI, the week-long hands-on training followed online coursework and taught participants critical techniques like metalcasting, forging, machining and plate rolling. With defense equipment heavily reliant on these methods and a projected 2.1 million manufacturing job shortfall by 2030, programs like METAL aim to close the workforce gap.

Read the full original story here.

New MTU-IACMI Partnership Expands Metallurgy Education And Outreach

Original source: Forbes

IACMI – The Composites Institute has partnered with Michigan Technological University (MTU) to expand the reach of the Metallurgical Engineering Trades Apprenticeship & Learning (METAL) program launched in 2024 to strengthen training in casting, forging, and plate rolling. Backed by the Department of Defense, the program combines online learning with hands-on boot camps to build a national pipeline of metalworking professionals. MTU joins other universities in delivering METAL’s curriculum and will offer programs to expose students to metallurgy and materials science. IACMI aims to grow the program’s footprint, including integrating hands-on experiences in high schools and establishing mobile training units.

Read the full original story here.

Igniting Curiosity: Casting Dreams Winner Noah Miller Creates and Imagines with Metalcasting

Noah Miller never thought he’d win the Casting Dreams competition. But after learning how to metalcast, refine, and finish a miniature truck in his high school’s material science class, he was ready to give it a try—and he took home the national prize.

Miller, 18, from Spring Hill, Kansas, got his first glimpse of metalcasting when his twin brother, Levi, won second place in the inaugural Casting Dreams competition last year. Through resources and materials provided by Foundry Educational Foundation (FEF) High School Outreach program, a METAL partner, Miller gained rare hands-on experience in a field he’d never learned about before.

But, more than anything, Miller was excited to cast a creation of his own.

“What made it interesting to me was how you can make a mold of something and pour metal and it comes out so detailed, so perfect,” Miller said. “My favorite part was pouring the metal into the mold.”

Miller credits his material science teacher, Matthew Lundy, for igniting his interest in metalcasting.

Firing Up Curiosity in Manufacturing

Lundy’s class introduces students to a variety of manufacturing disciplines—from ceramics and glass, to polymers, plastics and composites, to metal material properties and casting. Using FEF’s Foundry in a Box kits and video tutorials, he walks students through simple sand casts and tin casts before they explore investment casting with FEF Key Professor Russell Rosmait.

With Lundy and Rosmait’s help, students learn how to metalcast small items such as school mascots, sports team logos, rings and even their favorite books. Each student designs their project in CAD, 3D prints the design, encases the object in plaster to create a ceramic mold, and finally has the chance to pour red-hot bronze or brass into the desired shape.

“There’s not really any limitation,” Lundy said. “If you have the imagination for something that you want to cast and it can be made into three dimensions, you can cast it.”

For both Lundy and Rosmait, the best part is seeing students’ eyes go wide and light up during the molten pour. Rosmait, a professor emeritus of engineering technology at Pittsburg State University, has partnered with Spring Hill High School for more than eight years to show high school students what’s possible in a metalcasting career—and many students continue on to engineering programs at Pittsburg State and other schools across the country.

“Part of FEF is making sure students have great hands-on experiences,” Rosmait said. “I know I have a student hooked when I watch them pour the metal and their tongue is hanging out of their mouth. They’re just so excited and can’t wait to break out the mold and see their success.”

What’s most important is that students have the opportunity to try metalcasting, Rosmait added. “It teaches our youth today that you can build things to advance the future,” he said.

For Miller, entering the Casting Dreams competition was an opportunity he couldn’t resist.

Forging Ahead of the Competition

After learning the fundamentals of metalcasting, Miller was ready to design and cast his own creation for Casting Dreams.

In its second year, Casting Dreams is hosted by the Steel Founders’ Society of America for seventh through twelfth grade students who want to test the skills they’ve learned with help from programs like METAL and FEF. In 2024, Casting Dreams had 67 students participate. This year, more than 600 students submitted their own metalcasted projects to be judged by professional metallurgists.

Miller’s project was inspired by his love of working on cars with his dad. He spent a month perfecting his investment cast Ford truck (complete with hubcaps and bumpers) before submitting it to Casting Dreams. After placing second and third at the local and regional levels, Miller said he was surprised when he won at nationals.

“The most rewarding thing from participating in Casting Dreams was winning first place,” Miller said. “When I was making my truck, I felt most accomplished when I polished it up and saw how good it looked. It blew me away.”

With help from FEF Key Professor Russell Rosmait, Spring Hill High School senior Noah Miller investment-cast an antique Ford truck and submitted it to the Casting Dreams student metalcasting competition where it won the national grand prize.

Michelle Kerns, program director for FEF’s Metalcasting High School Outreach, said reaching students in high school and middle school is the perfect time to engage, inspire, and get them curious about metalcasting careers.

“By the time we reach engineering students in junior or senior year of college, they’ve already decided where they want to go,” Kerns said. “We’re trying to get the best and brightest students into the metalcasting industry. There’s a lot of jobs coming back to the United States and we need talented people in the workforce to fill those jobs and meet the needs of the foundries.”

For now, Miller plans to pursue his passion for science at Kansas State University, putting his Casting Dreams prize money toward tuition. More than the grand prize, Miller’s grateful for the hands-on metalcasting experience and skills he gained, thanks to his teacher and FEF.

Last year, FEF’s Metalcasting High School Outreach program piloted its two-week basic metalcasting unit in 13 schools. This fall, the program will launch in 50 high schools across the U.S. – teaching students of all ages how to create, imagine, and forge new paths in metalcasting.

For more information on METAL’s K-12 workshops, visit here.

Casting Dreams winner Noah Miller, fourth from left, stands with his classmates, teacher Matthew Lundy, second from right, and FEF Key Professor Russell Rosmait, far right, at the local Casting Dreams competition at Pittsburg State University.

Spring Hill High School senior Noah Miller won the national Casting Dreams student metalcasting competition, judged by professional metallurgists, with a bronze Ford truck he investment casted with the help of FEF mentors and resources.

U.S. National Science Foundation HAMMER-ERC at The Ohio State University Joins METAL

COLUMBUS, Ohio, June 1, 2025 – The Metallurgical Engineering Trades Apprenticeship & Learning (METAL) program is proud to announce a new partnership with the U.S. National Science Foundation Hybrid Autonomous Manufacturing – Moving from Evolution to Revolution Engineering Research Center (HAMMER-ERC) at The Ohio State University. This collaboration will advance cutting-edge training and curriculum in forging technologies as part of a national effort to strengthen and diversify the U.S. metal manufacturing workforce.

Led by IACMI – The Composites Institute® and funded by the Department of Defense’s Industrial Base Analysis and Sustainment (IBAS) Program, METAL equips learners at all stages with the knowledge and skills needed in critical areas like casting, forging, and plate rolling. NSF HAMMER-ERC will now serve as a key METAL hub, focusing specifically on the development and delivery of high-impact forging curriculum for technicians, engineers, and instructors across the country.

“At HAMMER-ERC, we are driving the evolution of manufacturing by integrating digital tools and forging science to meet the needs of today’s defense and commercial sectors,” said Glenn Daehn, program director for HAMMER-ERC. “Partnering with METAL allows us to scale this mission and deliver training that is as advanced and dynamic as the industry itself.”

HAMMER-ERC joins a growing network of METAL partners, including Ohio State University, the University of Alabama at Birmingham, Pennsylvania State University, and the University of Tennessee, Knoxville.

Where Ohio State’s foundry will serve as METAL’s hub for hands-on casting training, HAMMER-ERC will focus on forging. The forging curriculum will include a comprehensive suite of online training modules covering:

Industry 4.0 applications in forging, including sensors, automation, robotics, and cloud-based decision-making
Forging fundamentals and advanced metals manufacturing
Digital simulation techniques to bring real-world scenarios into virtual learning environments.

In addition to technical education, HAMMER-ERC will launch a “Master Instructor” credential—a train-the-trainer model designed to empower educators to teach advanced forging content at regional training centers, community colleges, and universities nationwide.

“The forging industry is rapidly transforming, and we need a workforce that’s ready to lead,” said Lucinda Curry, METAL National Workforce Manager at IACMI. “HAMMER-ERC’s leadership in simulation, data integration, and industry-relevant curriculum makes them a perfect METAL partner.”

As a METAL hub, HAMMER-ERC will also engage in industry testing and feedback loops to ensure the curriculum remains practical and forward-looking. Through collaborations with educational institutions and workforce training centers, the HAMMER-ERC team will help build a strong, sustainable pipeline of forging professionals equipped to meet modern manufacturing challenges.

Firing Up Success: William Goehl Launches His Manufacturing Career with METAL

During a week-long METAL bootcamp at the University of Tennessee, mechanical engineering student William Goehl gained the experience to design and forge a scratch mold, medallion and a mug through the investment casting process.

William Goehl always considered himself a jack of all trades. Growing up fixing old cars with his dad and driving go-karts inspired him to pursue a career in the high-performance automotive industry – and thanks to METAL, Goehl received the hands-on experience he needed to propel his career.

As the U.S. faces a surging demand for skilled metalcasting and manufacturing professionals, METAL, led by IACMI – The Composites Institute® with funding from the Department of Defense’s Industrial Base Analysis and Sustainment Program, is strengthening and diversifying the metal manufacturing workforce. With a focus on casting, forging and plate rolling, METAL’s workforce development programs deliver hands-on experience to people of all ages.

Goehl, a mechanical engineering graduate from the University of Tennessee, Knoxville, learned about METAL his senior year. Striving toward his dream of supporting the racing industry, Goehl focused his studies on material science and aerospace. He wanted a career where he could combine his engineering knowledge and creativity with the sport he loved, but he also knew the jobs he sought were extremely competitive.

He’d need a way to boost his chances – and his career.

“F1 race cars are like airplanes on the ground because their parts are made to airplane specs,” Goehl said. “With my educational background, I can do aerospace or automotive, which at the highest level are becoming one industry.”

Goehl specifically wanted to focus on engineering tight tolerances, or extremely precise measurements for maximizing performance, reliability and safety in manufacturing, especially at high speeds. A deeper understanding of metalcasting felt like the best way to get ahead and earn his spot in automotive and aerospace innovation.

Supercharged with Metalcasting

While most UT college students enjoyed downtime during spring break, Goehl was on campus gaining metalcasting experience in a week-long METAL bootcamp. Greg Harrell, a METAL workforce coordinator with more than 20 years of metalcasting experience, said Goehl’s curiosity and work ethic immediately stood out to him.

“Will always came in early and stayed late. He had valuable hands-on learning already instilled in him and that’s exactly what engineers need,” Harrell said. “You need to take what you learn in the classroom and be mechanically inclined to apply it. That’s such an advantage in the casting and forging industries.”

Through METAL’s online and in-person learning opportunities, Goehl got a first-hand look at the investment casting process – from mixing slurry for a mold, to firing up the furnace to strengthen the shell and Goehl’s favorite part, pouring molten metal to form the final product. He also observed sand casting for the first time which is often used to cast heavy machinery such as engine blocks, machine bases and wind turbine hubs.

Goehl previously attended an ACE bootcamp, another IACMI workforce development program that focuses on CNC machining. In the ACE program, Goehl designed and built an air piston engine for the first time. By applying dynamic techniques for drilling, roughing and finishing the engine, Goehl learned critical skills to manufacture an essential part used in pneumatic tools, lifting systems and assembly robotics in the automotive industry.

Goehl said these experiences were eye-opening and he wouldn’t have received this training anywhere else.

“The hands-on experience helps you learn what’s possible,” Goehl said. “You can design parts and think about how they’ll be made so we can make it easier for metalcasters who are doing the work every day.”

Thanks to his training in metalcasting, Goehl’s career has taken off in one of his dream fields – the aerospace industry.

Forging a New Path

After attending METAL’s bootcamp, Goehl applied at Howmet Aerospace, based in Morristown, TN, with his new credentials and was quickly met with a job offer within weeks of graduating. There, he’ll have the opportunity to apply his metalcasting experience to build molds for high-performance industry solutions, such as more fuel-efficient engines for airplanes and gas turbines and longer-lasting aluminum truck wheels.

Without METAL, Goehl said he wouldn’t be the mechanical engineer he is today.

“I probably still wouldn’t fully understand what I understand now. Learning about manufacturing and metalcasting in class and actually using casting methods are two different things,” Goehl said. “I will be an accomplished engineer quicker because of this program.”

Since 2023, METAL has trained 336 workshop participants, placed 16 interns and reached more than 2,000 prospective metal workers. Through university bootcamps across the country, METAL is planting the seeds of a brighter, more resilient future – showing students what’s possible in the vital, often overlooked, metallurgy industry.

William Goehl, a mechanical engineering student at the University of Tennessee, participated in printing 3D sand molds that were used to cast the base of an air piston engine during his METAL bootcamp, similar to the base machined during his hands-on ACE training experience.

William Goehl, left, pours slurry into a mold that will later be used in the investment casting process during a week-long METAL bootcamp at the University of Tennessee.

Anything is Possible: James Votava Forged a Future in Metalcasting with FEF

James Votava’s passion for building began as a kid with his legos. When the time came to choose a college major, mechanical engineering felt like the right fit, but his career path was unclear – until he discovered METAL’s Fo undry Educational Foundation (FEF) internship program.

Metallurgical Engineering Trades Apprenticeship & Learning (METAL) and FEF partner to address the critical workforce shortage in the casting and forging industry through hands-on learning experiences. As the U.S. faces a pressing need for 122,000 more skilled casting and forging professionals by 2028, this internship program is one way METAL is accelerating the development of a talented, adaptive and prepared manufacturing workforce. Bringing awareness to opportunities in metalcasting is the critical first step. Today, more than 24 FEF interns from 10 universities have worked on real-world casting, forging and plate rolling projects while gaining access to networking opportunities that shape their careers.

Votava, a 2025 graduate from Georgia Southern University, said the first time he saw a molten metal pour at an FEF open house, he was hooked. He started working with Dr. Mingzhi Xu, associate professor of mechanical engineering, who showed him what was possible when he combined his engineering skills with the art of metalcasting.

James Votava, far left, receives an FEF scholarship and is joined by his metalcasting professor and mentor Dr. Mingzhi Xu, far right, at Georgia Southern University.

“You design and bring your own metal creation to life,” Votava said. He began regularly attending meetings at his university’s foundry and decided metallurgy was the career he wanted to pursue. “I stuck with it and loved what I did. I realized this is something I would enjoy doing in the future.”

Turning Up the Heat on Metalcasting

After discovering the FEF program in 2021, Votava found new inspiration at the foundry. Collaborating with Xu and fellow casters-in-training empowered Votava to experiment, apply his ingenuity, and find solutions to unsolved problems.

His proudest moment was designing and manufacturing a new slurry mixer for his foundry group. Slurry, or the mixture of refractory powder, binding material, and carrier liquid used to create a metalcasting mold, must be combined slowly to avoid clumps. When GSU’s mixer needed an upgrade to hold and move more slurry, Votava was eager for the challenge.

“It was hands-on, and I was a freshman working on an actual engineering project,” Votava said. “Other people’s ideas helped me a lot, but that was something I worked on solely by myself and seeing it complete made me very proud.”

Thanks to the paid opportunities and scholarships provided by FEF, Votava spent his summers focused on projects like the slurry mixer, learning the pour process, and supporting his classmates’ metalcasting projects. He also participated in non-destructive iron tests, which used resonance frequencies, or natural vibration rates, to determine possible defects in metal materials. This research could help foundries avoid critical imperfections in ductile iron (commonly used in transportation, infrastructure, and heavy machinery) in the future.

“On the show ‘Forged in Fire,’ it looks like you just pour or hit out molds, and that’s not all [metalcasting] is – it’s more engineering,” Votava said. “I don’t think people understand you can create anything.”

Votava carried this innovative mindset with him into his FEF internship, and it powered a strong start to his career. In 2024, Votava and GSU’s metalcasting team came in first place at the American Foundry Society Southeast Regional Conference student competition. He also engineered a side cradle for the B-17 machine gun turret for another AFS conference.

Thanks to the skills, experiences, and connections Votava made through FEF, he believes the sky’s the limit for his career—and he shares the possibilities of metalcasting with younger students. When GSU won a Foundry Educational Foundation grant to build Foundry In A Box kits for local high schools, Votava helped lead the kit-building efforts.

“I enjoyed this opportunity because a lot of students don’t know about metalcasting. It’s really cool that through FEF we can reach out to these kids and then hopefully continue their interest when we graduate and get jobs,” he said.

Beginning his career is Votava’s next adventure.

Firing Up New Opportunities

Since graduating, Votava has accepted a job with C&H Precision Weapons in his hometown of Richmond Hill, GA. He’ll be able to apply everything he’s learned with FEF – from a deeper understanding of different metal properties to CAD simulations and metallurgy best practices – to the design and manufacturing of special projects in the firearms industry.

Votava credits this opportunity to Xu, his mentor and metalcasting professor, as much as to his FEF experience. If there’s one thing he could say to FEF’s sponsors and professors, it would be thank you.

“I am so grateful for this opportunity and FEF’s scholarships,” Votava said. “Without them, I would have needed another job instead of learning and researching with Dr. Xu. Instead, I’ve been able to focus on my academics, which has helped me get internships and jobs.”

Even though his next career move won’t be to a foundry, Votava isn’t giving up on that dream – a dream he didn’t know existed when he started college.

“Without FEF and Dr. Xu, I’d be going through life without knowing what metalcasting is,” he said. “FEF is helping younger generations discover an interest in something they might not have expected, learn hands-on skills, and then pass this knowledge down. Without these programs, metalcasting skills will be lost.”

His advice for up-and-coming metallurgists? Don’t give up and ask for help.

“A lot of freshmen get discouraged when they first start. Some things are hard to make, but if you have an idea, try to make it a reality,” Votava said. “You can create whatever you want if you put in the effort – and the foundry will help you along the way.”

James Votava, second from the left, celebrates with fellow metalcasters from Georgia Southern University after the team takes first, second, and third place in the 2023 American Foundry Society Southeast Regional Conference student casting competition.

James Votava, far right, and his metalcasting team from Georgia Southern University won first place in the 2024 American Foundry Society Southeast Regional Conference student casting competition.

James Votava, third from right, and his Georgia Southern University metalcasting team share their creations at the 2022 American Foundry Society Southeast Regional Conference.

James Votava, right, was awarded the Birtwistle Scholarship from FEF in 2024.

New METAL Hub Launches at the University of Alabama, Birmingham

BIRMINGHAM, Alabama, May 21, 2025 – The Metallurgical Engineering Trades Apprenticeship & Learning (METAL) program is proud to announce a new partnership with the University of Alabama at Birmingham (UAB) to enhance and scale up industry-driven training opportunities for current and prospective metalworking and manufacturing professionals. Led by IACMI – The Composites Institute® with funding from the Department of Defense’s Industrial Base Analysis and Sustainment Program, METAL strengthens and diversifies the U.S. metal manufacturing workforce, focusing on casting, forging and plate rolling.

“METAL’s partnership with UAB will increase workforce skills in skilled trades from the technician through engineering levels, providing a pipeline of personnel excited about the casting and forging industries,” said Lucinda Curry, METAL National Workforce Manager at IACMI. “By working together, we will increase capacity in the United States to meet both the needs of the commercial and national defense supply chains.”

The METAL program at UAB will offer both foundational and specialized training in metalworking and manufacturing, focusing on automation, casting, forging, and rolling techniques critical to the industry’s future. The UAB METAL hub will also teach principles in the metallurgical fields, such as heat treatment of ferrous and non-ferrous alloys. Participants will be doing a series of hands-on activities, including CAD design and 3D printing of patterns, casting, material testing, and machining.

Through a combination of online and hands-on training, including comprehensive in-person boot camps, UAB will provide hands-on experience and essential technical skills in metal melting, heat treatment and machining for individuals seeking to enter or advance in the manufacturing sector.

“We are excited to play a key role in shaping the future of manufacturing education and workforce development,” said Dr. Haibin Ning, UAB associate professor of materials engineering. “This partnership is an important step in addressing the challenges of modern manufacturing while providing students with the skills and credentials they need to succeed in the industry.”

UAB joins a growing network of METAL hubs, including Ohio State University, Pennsylvania State University, and University of Tennessee Knoxville, as part of a nationwide effort to expand access to high-quality, industry-relevant training. These university hubs expand the METAL network by fostering collaborations with local high schools, community colleges, and other educational institutions to create a pipeline of skilled workers for the U.S. manufacturing sector.

Through METAL’s multi-tiered curriculum, UAB aims to support workforce development by providing participants with academic credits, industry certifications, apprenticeships and degree tracks.

For more information about METAL, please contact:

Brittany Crocker
brittany@piper-communications.com
O: 865-329-0553 ext: 216

About METAL

Metallurgical Engineering Trades Apprenticeship & Learning (METAL), led by IACMI, is an industry-driven initiative aimed at providing high-quality, hands-on training in the metalworking and manufacturing sectors. The program is designed to address workforce development needs by offering comprehensive curricula in casting, forging and metallurgy, with an emphasis on automation and modern manufacturing technologies.

About IACMI

IACMI-The Composites Institute® is a 170-plus member community of industry, colleges and universities, national laboratories, and government agencies working together to benefit the nation’s energy, manufacturing, and economic security. IACMI is managed by the Collaborative Composite Solutions Corporation (CCS), a not-for-profit organization established by The University of Tennessee Research Foundation. A Manufacturing USA institute, IACMI is supported by the U.S. Department of Energy’s Advanced Materials Manufacturing Technologies Office, as well as key state and industry partners. It collaborates with the Department of Defense to scale up industry-driven job skills and revitalize American manufacturing.

METAL Meets Merit: Inspiring Young Minds at the Scouting America Foundry Workshop

METAL workforce training specialist Ralph Workman joined 24 Scouting America scouts from Michigan, Ohio and Rochester, New York at Kent State University for a metallurgy workshop.

The event, hosted by the American Foundry Society and the Lake Erie Council’s annual program, sought to spark interest in metallurgy through an experience that culminated in earning the Scouting America Metal Merit badge.

Earning the badge is a challenging achievement that requires hands-on experience in a foundry environment. Kent State University is one of only 25 colleges and universities in the United States that are accredited by the American Foundry Society to offer the program.

Scouts must demonstrate a deep understanding of metalworking safety, materials, and techniques—including the differences between ferrous and nonferrous alloys, how to harden and anneal metal, and how to identify career paths in the field. Most importantly, they must choose one of four advanced tracks—Sheet Metal Mechanic, Silversmith, Founder, or Blacksmith—and complete detailed projects that involve bending, joining, forging, or casting metal components.

At Kent State, scouts got a rare opportunity to melt metal in a real induction furnace, bringing their textbook knowledge to life in a dynamic lab environment.

During the workshop, Workman talked to scouts about online and in-person training opportunities in metallurgy.

“We showed a video from a Penn State bootcamp, just to give an idea of what kind of opportunities are out there to work with metal and what they can do moving forward if they’re interested,” Workman said.

A number of participants showed interest in exploring metallurgy as a career opportunity in the future, according to Workman.

Big thanks to Kent State University, the American Foundry Society and all the scouts who showed such passion and curiosity. We’re excited to see where your journeys take you!

METAL K-12 Initiatives

METAL is dedicated to inspiring the next generation of innovators by introducing K–12 students to the exciting world of metallurgy. Through hands-on, age-appropriate workshops, METAL aims to spark curiosity in metalcasting and forging while connecting students with real-world STEM applications and career pathways often overlooked in traditional education. Our K–12 programs are designed to be both educational and fun, offering students a chance to explore the science behind metals in a memorable, interactive way.

Highlights include miniature foundry experiences where students cast their own small metal objects using safe, low-temperature alloys, as well as forging activities with malleable materials. These engaging experiences allow students to add a personal touch by choosing their own shapes, while learning key concepts in metallurgy and manufacturing.

METAL also proudly supports STEM fairs, encouraging young learners to dive deeper into the world of materials science.

Learn more about METAL K-12 Opportunities here.

METAL Wows at Grainger County World of Work Fair

RUTLEDGE, Tenn. — The METAL team joined more than 75 business and industry leaders at the Grainger County Schools Career and Technical Education World of Work (WoW) Fair on Tuesday, April 29, to showcase career opportunities to local students.

The event welcomed over 1,300 Grainger County students from grades 7-12 to explore interactive career fair booths and learn about careers in a wide range of industries.

At the METAL booth, METAL Workforce Coordinator Greg Harrell and other IACMI facilitators led students through an interactive sand casting experience. Students packed their own sand molds and took them to a METAL facilitator to see aluminum pour into the molds (referred to as casting). The end result? An aluminum METAL keepsake to take home.

While the aluminum cooled, METAL team members spoke with students about careers in the skilled trades and the pathways available through technical education and apprenticeships.

“Seeing them put the metal into the sand was really cool,” said Marley Hipshire, a senior at Grainger County High School. “They were showing us that this is a job you can do in the future that doesn’t take a lot of schooling like some other pathways.”

METAL focuses on equipping students with real-world skills and industry knowledge through structured learning and mentorship. METAL’s participation in the WoW Fair provided another outlet to spark curiosity and encourage students to consider high-demand, hands-on careers that contribute to the advanced manufacturing industry.

“There’s a gap in the workforce for metallurgical trades and skills out there,” said METAL Workforce Coordinator Greg Harrell. “Being in schools and exposing students to things like casting and forging that they would not ordinarily be exposed to ignites interest in this field and helps us build a pipeline.”

“Just making the cast parts and showing them how simple keepsakes like pendants and paperweights can be made demonstrates how things in the real world are made, whether that’s parts for vehicles, ships or submarines,” Harrell said.

For more information about METAL, visit www.METALforAmerica.org. To get started with a free, eight-hour course on casting, register for our online training. Bootcamps are also now open for registration at various locations

New METAL Hub Launches at Michigan Technological University

HOUGHTON, Michigan, May 8, 2025 – The Metallurgical Engineering Trades Apprenticeship & Learning (METAL) program is proud to announce a new partnership with Michigan Technological University (MTU) to enhance and scale up industry-driven training opportunities for current and prospective metalworking and manufacturing professionals. Led by IACMI – The Composites Institute® with funding from the Department of Defense’s Industrial Base Analysis and Sustainment Program, METAL strengthens and diversifies the U.S. metal manufacturing workforce, focusing on casting, forging and plate rolling.

This partnership will provide hands-on and online workforce training designed to strengthen the casting, forging, and machining industries.

As METAL’s newest hub operator, MTU will deliver METAL’s nationally recognized curriculum, facilitate instructor certification, and launch boot camps and academic pathways tailored to current and future metalworking professionals. MTU will also integrate METAL training into its Summer Youth Programs to offer an immersive introduction to metalworking, metallurgy, and materials science to high school students from across the Upper Midwest.

“This partnership builds on Michigan Tech’s deep roots in materials science and engineering, as well as its strategic location in the Upper Midwest, a region vital to the U.S. manufacturing base,” said Lucinda Curry, METAL National Workforce Manager at IACMI. “Michigan Tech is an ideal partner for this mission, and we’re excited to work together to provide valuable metallurgical training in the manufacturing heartland.”

The MTU hub will implement a stacked curriculum model, which combines interactive online learning with immersive in-person casting and forging boot camps at MTU’s state-of-the-art labs. Future educational modules will incorporate training on automation in casting and forging, and will open pathways to employment in critical industry roles.

“Michigan Tech is proud to be part of METAL’s mission to revitalize and future-proof the American manufacturing workforce,” said Alexandra Glover, Assistant Professor in the Materials Science and Engineering Department at Michigan Tech. “By leveraging our longstanding educational programs focused on metallurgical engineering and strong industry partnerships, we are preparing students with both the foundational and advanced skills needed to thrive in the evolving industrial landscape.”

MTU joins a growing consortium of METAL hubs, including University of Alabama in Birmingham, Ohio State University, Pennsylvania State University, and the University of Tennessee in Knoxville. Together, these institutions are driving a nationwide resurgence in metallurgical and manufacturing excellence by expanding access to high-quality, industry-relevant training.

For more information about METAL at Michigan Tech, please contact:

Brittany Crocker
Email: brittany@piper-communications.com
Phone: 865-329-0553 ext: 216

About METAL
Metallurgical Engineering Trades Apprenticeship & Learning (METAL), led by IACMI, is a national initiative that provides industry-aligned training in casting, forging, machining, and metallurgical processes. With a focus on automation and advanced manufacturing, METAL aims to create a skilled, adaptable workforce prepared to meet both commercial and defense manufacturing demands.

About IACMI
IACMI – The Composites Institute® is a national public-private partnership focused on advancing composite materials and process technologies. Supported by the U.S. Department of Energy and the Department of Defense, IACMI brings together over 170 members from industry, academia, and government to drive manufacturing innovation and workforce development.

About Michigan Technological University

Michigan Technological University is an R1 public research university founded in 1885 in Houghton, and is home to nearly 7,500 students from more than 60 countries around the world. Consistently ranked among the best universities in the country for return on investment, Michigan’s flagship technological university offers more than 120 undergraduate and graduate degree programs in science and technology, engineering, computing, forestry, business, health professions, humanities, mathematics, social sciences, and the arts. The rural campus is situated just miles from Lake Superior in Michigan’s Upper Peninsula, offering year-round opportunities for outdoor adventure.

Magic of Metallurgy brings ‘Wizard of Oz’ Character to Life at Seymour Primary School

Students at Seymour Primary School recently experienced metallurgy first-hand during a live sand casting demonstration at the school’s annual Book Bash celebration. METAL (Metallurgical Engineering Trades Apprenticeships & Learning) and IACMI – The Composites Institute® supported the event by showing students how metal is shaped through a process called sand casting.

This year’s Book Bash book selection was The Wizard of Oz. Seymour Primary’s Book Bash is an annual celebration of reading that brings the entire school community together. For one month each year, students, staff, families and friends all share the experience of reading the same book. The story inspired school-wide participation in a STEM-focused sand casting presentation, where METAL facilitators used a mold of a Tin Man figurine to pour metal into, bringing the iconic character to life.

The Tin Man casting project served as both a technical demonstration and a creative introduction to the magic of metallurgy, perfectly paired with the school’s elaborately decorated halls, featuring a yellow brick road and an Emerald City.

The Process of Casting the Tin Man

Sand casting is one of the oldest metal fabrication techniques; The process uses compacted sand to form a mold around a solid pattern of the desired object.

Prior to the event at Seymour Primary, team members at the University of Tennessee School of Art and the Tickle College of Engineering collaborated to investment cast a headless Tin Man’s body and base. During the demo, instructors created the Tin Man’s head mold by tightly packing specialized sand around a 3D-printed pattern. Once the mold was removed and the cavity formed, instructors melted tin to over 600°F and poured it into the mold.

The room erupted into ‘oohs’ and ahhs’ when students learned the metal had to be heated to 600 degrees. After cooling, instructors broke the sand mold away, revealing a solid metal replica of the Tin Man’s head.

Igniting Curiosity Through Creativity

“We’re taking a character from the book, the Tin Man, and we’re talking about engineering principles, like 3D modeling, 3D printing and metal casting,” said Stephen Sheriff, Process Engineer and Research Associate II at the University of Tennessee’s Fibers and Composites Manufacturing Facility in Knoxville. “But beyond the science, it’s about sparking creativity, whether it leads to a career or just a new curiosity.”

Following the demonstration, students were curious and eager to ask questions. They wanted to know where the metals came from, what materials can be melted and how various metals are molded.

Building the Workforce of Tomorrow

Sand casting demonstrations aren’t just about science; they help students explore future opportunities in critical career fields.

“We’re hoping to spark students’ interest in trades like metallurgy and help fill critical workforce gaps in areas like ship and submarine building for the Department of Defense,” said Greg Harrell, Workforce Coordinator at IACMI.

METAL is part of a larger effort, supported by the Department of Defense, to build a robust pipeline of skilled tradespeople. By introducingthese concepts early, the METAL program aims to inspire the next generation of metallurgical engineers, technicians and craftsmen.

“The key takeaway is that this kind of creativity and problem-solving isn’t out of reach,” said Sheriff. “With some imagination and the right tools, an idea can become a finished project.”

Interested in Hosting a Workshop or Live Demonstration?

Sand casting is just one of the many techniques METAL uses to introduce students to the world of casting, forging, manufacturing and design.

Demonstrations like these offer students a firsthand look at traditional metalworking processes, helping them understand how raw materials are transformed through engineering and craftsmanship. Watching an idea come to life shows students the diverse applications of metallurgy – both creative and functional – and offers an introduction to the industry.

To learn more, visit: metalforamerica.org

Apprenticeships Strengthen the U.S. Industrial Workforce

On National Apprenticeship Day, Metallurgical Engineering Trades Apprenticeship & Learning (METAL) recognizes the powerful impact of apprenticeships in addressing workforce gaps and supporting the U.S. defense and industrial bases.

The need to fill major gaps in the U.S. defense workforce is critical. Between now and 2028, the U.S. defense industrial base is projected to require at least 122,000 additional skilled professionals, including shipbuilders, engineers and others in critical roles supporting the Department of Defense.

As defense manufacturing competes with other sectors for these critical workers, failure to meet the growing demand for skilled professionals could exacerbate vulnerabilities within the defense industrial base and the U.S. manufacturing economy.

Photo courtesy of Scot Forge

Training Partnerships Drive Success

METAL, led by IACMI – The Composites Institute, has a strategic partnership with Jobs for the Future (JFF) to provide apprenticeship opportunities that strengthen the nation’s metalcasting workforce while supporting the security and sustainability of America’s defense and manufacturing industrial bases.

METAL also provides consulting services, connections to funding opportunities and apprenticeship curriculum for companies to create custom training and on-the-job learning experiences.

A good example of this is Goodwin Engineering Training Company. Goodwin partnered with METAL to share their highly successful apprenticeship model and curriculum to address critical skill gaps in the metal manufacturing workforce – their model is “a radical, new approach needed to raise the skill level of the individual worker to the standard that they required for future growth” said Natalie Jellyman, Goodwin Apprenticeship Manager.

By combining METAL’s workforce development mission with Goodwin’s proven training expertise, our partnership has delivered a specialized curriculum that integrates classroom instruction with practical, industry-relevant experience.

The curriculum can be easily adopted by companies that want to implement a turn-key apprenticeship program at no charge. In some cases, incentive funding is available to launch the new program.

“We can learn so much from textbooks, from word of mouth,” said Lee McCue, Teacher at Goodwin Engineering Training Center, “But actually doing the job itself, and putting that knowledge into practice is where you find your feet and find those experiences.”

Apprenticeship programs, like the one at Goodwin, tackle workforce shortages, strengthen national security, boost U.S. economic competitiveness and build lasting career pathways in U.S. manufacturing.

Apprenticeships in Action

You can see the impact of apprenticeships in action at CWC Textron, a leading manufacturer of high-quality castings for the automotive and industrial sectors.

CWC Textron’s apprenticeship pipeline provides apprentices with skills in machine repair, millwrighting and electrician apprenticeships.

“By investing in apprenticeships, companies can support the development of individual careers and secure their future and the industry’s future,” said Holly Rolewicz, apprenticeship program lead for CWC Textron. “These trades are vital to our success, particularly in maintaining a foundry that has been operational for 117 years and relies on aging equipment.”

Apprentices from CWC Textron

For more information on apprenticeship opportunities and curriculum development, connect with Lucinda Curry at lcurry@iacmi.org.

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