Great Question Podcast: Forming Metal Heads: How To Address the Metals Casting and Forging Skills Gap

Check out this episode of Great Question: A Manufacturing Podcast featuring METAL Program Manager Mike Kubacki.

Manufacturers understand the skills gap: every day they recognize that do not have enough people or enough of the right people to execute the difficult and sometimes dirty, often dangerous tasks like pouring and forming molten materials, grinding or machining parts, treating and handling those parts, welding and finishing components and systems, etc. It’s more than a practical problem. It’s an economic and institutional crisis.

The Metallurgical Engineering Trades Apprenticeship and Learning program (METAL) established by the Dept. of Defense in 2024 is moving fast to resolve it, setting up and coordinating practical training in critical disciplines for metal casting and metal forging processes at seven universities, and drawing in fresh minds who ensure that knowledge and practical understanding continue to be available to engineers and investors in the decades ahead of us.

Mike Kubacki, program manager for METAL describes the program and its progress.

The Manufacturing Executive Podcast: Chocolate Castings, Apprenticeships and the Future of Manufacturing Careers w/ Mike Kubacki

Don’t miss this episode of The Manufacturing Executive where host Joe Sullivan sits down with METAL Program Manager Mike Kubacki to discuss the METAL initiative.

The workforce crisis in US manufacturing isn’t just a challenge – it’s a national security risk. This is particularly true in casting and forging, where today’s guest Mike Kubacki has spent two decades. In our conversation, he explores the urgent need to rebuild America’s industrial base, the reality behind modern manufacturing environments and how innovative programs are connecting hands-on learning with next-generation careers. We’ll learn why engaging students early, supporting employee growth and linking frontline work to real-world impact are key to the future of US manufacturing.

Anderson County Students Experience Forging Firsthand at UT Knoxville

Original source: WBIR

Students from Anderson County, Tennessee, recently visited our partners at the University of Tennessee, Knoxville (UTK) for an immersive, hands-on forging workshop. During the session, students explored the properties of metal through a series of interactive activities that connected classroom concepts with real-world applications in metallurgy and materials science.

Their first activity was clay forging, which introduced them to the behavior of metal under heat by using modeling clay to simulate how metal behaves during the forging process. Students practiced drawing out and upsetting the clay, then pressed images into their finished pieces before setting them to cure.

Next came sand casting, where students used their 3D-printed designs from school to create molds and pour molten tin, transforming their digital models into tangible cast shapes. Meanwhile, small groups took turns participating in induction forging, heating metal “lollipops” until they were red hot, then hammering their initials into them.

Watch the full coverage here

Pouring Metal and Powering National Defense: DoD Contractors Join METAL Bootcamp

Melissa Walston and Rachel Reed have spent their careers traveling the world, learning languages and guiding U.S. diplomats across foreign nations and cultures. But when it came to navigating a foundry for the first time, they felt lost.

In their new roles as Department of Defense contractors with Vision Point Systems, Walston and Reed support metal manufacturing projects for the Navy’s Carderock Naval Surface Warfare Center. Carderock is the Navy’s premier center for engineering, modeling and testing ships and ship systems. Its mission spans ship design, naval architecture and the strength of the structures that keep sailors safe at sea. At its core, both Carderock’s success and the future of U.S. defense rely on one critical capability: consistent, high-quality metal production.

“Metal is in everything,” said Reed, who’s a program analyst. “The Naval Service Warfare Center and other government agencies require a strong base of manufacturers who can provide the materials we need at the scale and to the specification we need—and that’s not easy.”

Reed joined Vision Point Systems in February after 15 years managing international exchange programs and delegation visits. Her superpower? Connecting the right people and organizations, no matter where they’re from. Now Reed coordinates contracts between metal manufacturers and the Navy. But to lead this collaboration, she needed to understand the world of metallurgy.

“When I first did an audit visit at a foundry, it was awesome, but it was also confusing,” said Reed. “The terminology was so unfamiliar to me, it was like a different language.”

Reed, who is fluent in Japanese, knew she had to approach her new job like she was preparing for a trip—immersing herself in casting, forging and manufacturing culture. Her colleague, Walston, recommended METAL’s week-long metallurgy bootcamp at Penn State University to Reed.

“I immediately started telling my coworkers, ‘you guys have to take this course.’ It will help so much because none of us came from this world,” Walston said, referring to manufacturing.

Walston, who’s a program coordinator at Vision Point Systems, has led American ambassadors around the world, tracked missions in the U.S. Air Force, and served as an executive assistant at the White House. Her career, nothing short of a Disney World ride (she worked there, too), is now focused on reigniting the nation’s defense manufacturing capabilities.

“I’ve spent most of my life, in one way or another, supporting my country,” Walston said. “It means a lot to me to be doing something that is directly helping our military. I know what it feels like to be one of them, waiting for a part to be fixed or made.”

Off to Bootcamp

Walston decided to try Penn State’s METAL bootcamp after her Vision Point Systems orientation, when she realized she had no idea what a Charpy was.

“I sat in this meeting and almost every briefer brought up the term ‘Charpy.’ I kept laughing to myself saying, ‘I know they’re not talking about the pen in my purse,’” she said—they weren’t. In metalcasting, a Charpy, pronounced like “Sharpie,” is a type of test used to measure the material’s toughness when struck with sudden impact.

Walston quickly learned “Charpy” wasn’t the only term she’d need under her belt to support the defense industry’s metal pipeline. “I thought my head was going to explode. I didn’t understand most of what I heard,” she admitted.

An introduction to metallurgy terminology and science—from casting and heat treatment to nonferrous metals and alloys—is exactly where METAL’s online training starts. Led by IACMI – The Composites Institute®, with funding from the Department of Defense’s IBAS Program, METAL is building a highly-skilled, adaptable manufacturing workforce with K-12 workshops and hands-on bootcamps for career seekers.

As more metal workers retire, the U.S. faces a critical knowledge gap. By 2033, manufacturers could need more than 2 million additional workers to keep up with supply chain and national security needs.

“Right this moment, we cannot entirely build a U.S. naval ship in the United States,” Walston said. “You don’t know what the future’s going to hold, and we need to be self-sufficient. If there’s a surge, we need to be able to meet that demand.”

Through partnerships with Penn State and universities across the country, METAL bootcamps are forging the next generation of industry leaders and innovators. Walston signed up without hesitation when she learned she could support her country by melting, casting and forging metal.

For one week, Walston and Reed suited up in safety glasses and fire-resistant gear to bring the science of metalcasting to life. From designing 3D molds to melting aluminum and bronze to machining a finished part, they experienced exactly what it takes to create a casting with their own hands.

Reed said the highlight of the bootcamp was firing up the foundry furnace for her first pour. After aluminum is heated to about 1,300 degrees Fahrenheit and liquifies, participants get the rare chance to carry the ladle and pour metal into the mold themselves.

“It was so cool. I’m never going to have that opportunity again,” Reed said. “It gave me a real respect for the work that our manufacturing partners do and how complicated it can be.”

Walston said she might have had a different career if she’d known what was possible in metal manufacturing sooner.

“If I had been introduced to the foundry when I was in high school, that would’ve been where I wanted to be—working with my hands, getting dirty, playing with fire, and getting paid for it,” Walston said. “I was on cloud nine.”

Both Walston and Reed returned home with their own creations—a bronze medallion and an aluminum stein—and a deeper understanding of what the Navy needs from metal manufacturers.

The Secret Weapon to Career Success

Since graduating from METAL’s bootcamp, the contractors feel like they’re finally speaking the same language as their metallurgy and manufacturing partners. Reed said she’s not only better equipped to have technical conversations, but she knows what a foundry needs to be successful.

“Every place is a culture, and METAL was my cultural introduction to working with manufacturers,” Reed said. “There’s a lot of time dedicated to keep a foundry running. I learned more about how they operate and the costs associated with producing a part.”

She strongly encourages anyone who supports the metal industry—or is curious about a fulfilling, well-paid career—to experience the bootcamp for themselves.

“We need more people interested in manufacturing,” Reed said. “Programs like METAL are essential because a lot of people are afraid of what they don’t understand. If you can get hands-on experience and realize the opportunities that exist, that is the real strength of this program.”

What Walston found in the foundry was confidence. Now she asks the right questions, keeps pace in meetings, and uses her growing expertise to help safeguard America’s metal production—and its future.

“I owe so much of my progress to this course,” she said.

Ready to cast a stronger career and a stronger America? Register for our free online training then visit our events page to attend the next METAL bootcamp near you.

Penn State Industrial and Manufacturing Engineering Professor Robert Voigt, Melissa Walston, Professor Paul Lynch and Ralph Workman celebrate Walston’s graduation from Penn State’s METAL bootcamp.

Rachel Reed graduates from METAL’s week-long, hands-on bootcamp experience with students and fellow industry professionals who expanded their skills in metallurgy.

Changing Lives: Manufacturing Works Fuels Ohio’s Metal Industry with Registered Apprenticeships

Manufacturing Works has been the right hand of Northeast Ohio’s manufacturing community for nearly 40 years. Through life-changing apprenticeships and strategic funding, the organization helps manufacturers grow their talent and produce high-quality parts faster. Now, at a pivotal time for our nation, Manufacturing Works is forging a skilled workforce for the metal industry.

Foundries today need one thing: people. More than 65% of manufacturers said attracting and retaining talent is their top business challenge, according to a 2024 National Association of Manufacturers survey. By 2033, almost 4 million manufacturing jobs will be available in the U.S., but half could go unfilled due to an unprecedented skills gap in the workforce.

Beth Dawson, director of apprenticeship programs at Manufacturing Works, explained that the COVID-19 pandemic catalyzed the nation’s labor shortage. Before the end of 2020, almost 29 million Baby Boomers in the U.S. retired—200% more than in 2019.

“When you look at the skilled workforce in manufacturing, most of them are planning to retire,” Dawson said. “The need for new talent and knowledge transfer is critical.”

Casting Solutions to the Talent Crisis

When metal workers are in short supply, America’s strength is, too. Metalcasting, forging and rolling are vital for producing fighter jets, naval ships, weapons, and components in transportation, medical and agricultural industries.

In April, the White House issued an executive order to ensure national security and economic resilience related to critical minerals like metal and its manufactured products.

“A strong national defense depends on a robust economy and price stability, a resilient manufacturing and defense industrial base, and secure domestic supply chains,” President Trump wrote.

Together with METAL and Jobs for the Future (JFF), group sponsors like Manufacturing Works are part of the solution. Manufacturers, who are often short on time and budget, can partner with group sponsors to manage apprenticeships and workforce development programs for them, JFF’s Director of Solutions Design and Delivery Mark Genua explained.

“It’s an easy lift for small to mid-sized employers. They could have an apprentice the next day,” Genua said. “Instead of taking the time to develop a program, employers can do what they do best—train.”

METAL, led by IACMI – the Composites Institute and supported by the Department of Defense’s IBAS program, and JFF work with community colleges and nonprofit organizations across the country to administer apprenticeship programs for metal manufacturers. Through this partnership, casting, forging, and plate rolling companies can access up to $24,000 per year for in-person or online learning programs. The funding can cover training equipment and trainer costs, curriculum development, program design and implementation, and support services for apprentices. Manufacturing Works was awarded incentive funding from JFF through METAL earlier this year.

So far, JFF and Manufacturing Works have sponsored and supported seven forging apprentices. But this is only the beginning. Since Dawson joined Manufacturing Works in 2020, the organization’s apprenticeship programs have grown 400%—making it clear, manufacturers need help.

“I met a company with machines that can produce 30,000 parts a day,” Dawson said. “But because they don’t have the talent to run the machines, they’re only producing 14,000 parts. Think about what that does to their production.”

Dawson works closely with her teammates Angilique Cole, workforce program and data coordinator, and Tiffany Rashada, director of strategic marketing, to connect manufacturers with apprentices—and transform metal workers’ lives.

Training Metal Workers—And Changing Lives

In Northeast Ohio, the road to a manufacturing career can feel out of reach. Many residents face hurdles that extend far beyond the foundry—from reading and transportation to the high cost of childcare. In East Cleveland, where household incomes are around $37,500—less than half the national average—families must overcome steep economic challenges.

Most apprenticeship programs take about four years to complete. But when metal workers graduate, they have the skills to support a fulfilling, in-demand career, with salaries starting at $57,500 a year, according to Manufacturing Works’ data.

That’s exactly what Manufacturing Works’ apprentice Alexandra Wagoner was looking for.

“I wanted to go into a career path that wouldn’t require a long academic education,” Wagoner said. “This is the only option for me that provides a stable career without needing a bunch of college.”

When Manufacturing Works visits high schools, Dawson said their goal is to help students and parents see the potential and career opportunities the metal industry offers.

“Their earning potential coming out of college is likely going to be lower than a journey-level person completing their apprenticeship, and with an apprenticeship, they won’t have college debt,” Dawson said.

Cleveland is also one of the most diverse cities in Ohio. To help apprentices and metal workers find success, manufacturers need to build welcoming environments with a strong learning culture, Rashada said.

“Most manufacturers care about employee engagement and retention,” Rashada explained. “But to even engage people that are non-traditional in manufacturing, your culture matters.”

With a deep passion for their communities, the Manufacturing Works team is dedicated to helping Ohio’s manufacturers overcome workforce challenges. Through mentorship, supervisor training, high school outreach and math- and literacy-focused pre-apprenticeships, Manufacturing Works is forging an industry where metal workers thrive.

Thanks to Cole, manufacturers can trust that their apprentices are on the track to success.

“I have to fuss at them sometimes, but it is all for the good,” she joked. “I just want them to let me know if they encounter and stumble across anything, professionally and personally. We can get over this hump together.”

Cole said the most rewarding part of her job is seeing people’s humble beginnings before finding a career in manufacturing.

“When they get to the finish line, I’m probably more emotional than they are,” she said. “They don’t realize the difference they’ve made in their lives.”

Ready to forge a stronger workforce? Apply for JFF’s apprenticeship incentive program here.

Cast a new career: Register for our free online training, then visit our events page to attend the next METAL bootcamp near you.

Penn State’s Sand Science Bootcamp Sparks New Thinking Across the Foundry Industry

In October, Penn State hosted its first METAL Sand Science Bootcamp, a hands-on course exploring the chemical and physical principles behind green sand and chemically bonded sand. These are two essential materials used to create molds for casting metal parts. From engine blocks and pipe fittings to aerospace and defense components, these molds form the foundation of American manufacturing.

Led by IACMI – The Composites Institute®, with funding from the Department of Defense’s IBAS Program, METAL is closing critical labor gaps in U.S. metal manufacturing. By 2030, almost 4 million manufacturing jobs will need to be filled, from entry level positions to trained production workers and specialized engineers. However, half of those positions might be left empty—putting the supply chain and our national defense at risk.

The free course encouraged participants to connect theory with practice and return home ready to improve their operations. A large contingent of industry professionals attended this bootcamp and came away with many new insights.

“I appreciated the collaborative conversation about broad topics and how it relates to what we’re doing in the real world,” said Olin Covington from Benton Foundry.. “Hearing from foundries, coremakers, sand guys—brainstorming and sharing. Mold energy was the best topic. The industry does drag its feet on certain things, but metalcasting has been around for thousands of years and there’s a reason it’s still here.”

For Justin Kinslow of Victaulic, the session on advanced oxidation stood out. “I hadn’t been exposed to that before. It ties into other projects we’re working on. I liked the setup—enough guidelines for it to be effective but informal enough for good conversations. I learned about other foundries and people.”

Penn State Professor Dr. Paul Lynch, Justin Kinslow with Victaulic, Penn State Professor Bob Voigt, and METAL Workforce Manager Greg Harrell.

His colleague Ian Erb, a plant manager at Victaulic, agreed that the course offered clarity: “I had some misconceptions about the theory behind mulling to energy. Glad I was here to crystallize exactly what we need to do. Pretty clear actions we’ll take when I get back.”

Joe Kramer from CWC Textron, where his team produces about 40,000 crankshafts a year, found the content directly applicable to ongoing projects. “We got some info on specific stuff we’re looking at: bond reclamation, a subset of advanced oxidant. CWC is the odd one out in scope and process, but it was nice to get a glimpse at what different shops look like. We also discussed 3D printing core molds, which is a new technology for us.”

For Bryan Rash of Spring City Electrical, the best part was realizing how much others share the same challenges. “Spring City is insular with our production, so it was nice to hear and see what other people have. Even though we’re low volume, we deal with some of the same struggles—not just technical, but hiring too. 3D sand printing on the design end, the basics of science—I’m not necessarily exposed to the difficulty of sand, and this helped me be aware of that on the front end.”

On the supplier side, Jim Kundratic of Badger Mining Corporation saw a broader opportunity for the industry. “I like where the program is going. I see a lot of foundries that need this program. We need more people to come in and learn the basics. The next piece is to promote it internally to my customers. Leadership is strained because they’re the only ones who know these things, and mid- to high-level management gets burned out.”

The Sand Science Bootcamp is part of a growing effort to equip metalworkers with the knowledge to optimize their systems and push new technology forward. As course leader Paul Lynch summarized, “The goal is for people to take these ideas back to improve their systems. What are the challenges? What are the opportunities?”

Want to get involved? Register for our free online training then visit our events page to attend the next METAL bootcamp near you.

Bringing Back the “Knowhow”: How Penn State Rebuilds America’s Manufacturing Workforce

Paul Lynch grew up in a town that hummed with manufacturing. In a small community hugging the Appalachian mountains of eastern Pennsylvania, he learned first-hand the impact foundries can have on the local economy. Today, Lynch is honoring the past by driving the future of metal manufacturing forward.

Dr. Lynch, who’s an associate professor of industrial engineering at Penn State Behrend, has dedicated his career to supporting the growth and innovation of Pennsylvania’s metal industry. Like many towns in the region, Lynch’s hometown, Gordon, was developed in the 19th century from the booming anthracite coal industry. For more than 150 years, coal mining powered homes, jobs and the economy—and fueled U.S. steel production.

“My dad owned a mechanic shop and he could tell you, without talking to the folks from the local foundry, if business was up or down,” Lynch explained. “If people are doing really well, they’ll buy new tires, or if they’re not, they’ll put off maintenance on their car. That’s how important manufacturing was to our area.”

The state’s deep history of enterprise manufacturing continues today. Pennsylvania is in the top five states for the most foundries in the nation. Its top manufacturing exports are computer and electronic products, machinery, primary metal manufacturing and transportation equipment—multi-billion dollar industries that require metalcasting, forging and rolling.

But the future of manufacturing in Pennsylvania – and our nation – depends on metal workers.

In partnership with METAL, Lynch and his colleagues at Penn State University are rebuilding the manufacturing workforce and bringing metalcasting back to American communities.

Advancing U.S. Manufacturing

With universities across the country, METAL is rekindling metallurgy for job seekers and students of all ages with unique, hands-on casting and forging experiences. Lynch couldn’t wait to get started at Penn State.

“I can tell you our leadership, from our chancellor to myself and the faculty, everyone here is so excited about this program,” he said. “If you talk to somebody that works in the industry, they’ll tell you this has been needed for 30 years.”

Since 2024, METAL team members at Penn State Behrend and Penn State University Park

have taught 12 K-12 workshops with 150 students and eight bootcamps, where 115 participants graduated with foundational and specialized metallurgical skills.

Through bootcamps that cover cutting-edge topics like the science behind sand casts and virtual reality applications, Penn State aims to upskill metal industry professionals. Advanced bootcamps are also open to beginner bootcamp graduates who want to expand their expertise.

In the new Sand Science Bootcamp, which launched in October, participants explored the chemical properties of green sand, or sand that’s bonded by clay, and chemically-bonded sand. Both materials are used in manufacturing to create molds that liquid metal can be poured into for casting metals. These molds can be used to create engine blocks, pipe fittings, agricultural and construction tools, and core components for the aerospace and defense industries.

Lynch hopes the advanced bootcamps will equip metal workers to optimize operations—and push innovative technology forward. “How can people take these ideas back to improve their systems?” he asked. “What are the challenges? What are the opportunities?”

In November, the university plans to host a level three advanced bootcamp for digital technologies in casting. The online lessons, which include data analytics, are already available. In the foundry, participants will learn how to incorporate immersive technologies like virtual

reality, along with sensors, data analytics and additive manufacturing, into the casting process.

In addition to strengthening today’s manufacturing workforce, Penn State inspires students and career changers to become the metal workers of tomorrow.

Learning Casting—From the Ground Up

Lynch said the goal for elementary, middle and high school workshops is to capture students’ interest—and their imagination. Every week this summer, students from ages six to 14 brought metallurgy to life. They assembled parts, crafted their own sand molds, and poured liquid aluminum into starfish, softballs and smiley faces. Students also had opportunities to practice their new skills, casting chocolate.

“Research shows that as early as five and six years old, children are connecting the dots, thinking about what they like and putting that toward a career,” Lynch said. “You want to get them thinking about metals and metallurgy, and you want the parents to understand the career opportunities that exist for the students now and in the future.”

Penn State’s beginner bootcamps, on the other hand, are designed to teach adults the metalcasting skills needed to explore and start a new career. Participants start their learning at home with METAL’s free, self-paced online training. Then, with a glimpse of metallurgy, college students, professionals and job seekers are ready for the hands-on METAL bootcamp experience.

For four days, the casters-in-training meet at Penn State to learn about life and work in a foundry. Participants who attend the beginner bootcamp learn industry terminology, design and print 3D molds, and finally pour molten metal into new, solid creations. They also cover the basics of heat treatments, forging and machining—all skills required to deliver a finished part.

“I was surprised by how many pieces we created from beginning to end,” said Rachel Reed, a program analyst at Vision Point Systems who attended the August bootcamp. “You actually walk away with a lost foam casting that you made yourself and a cast medallion. I left with a big goodie bag of things I made, and that’s just an awesome feeling.”

At the end of the day, Lynch believes the real driver of manufacturing’s future won’t be machines or automation—it will be people.

“I don’t care if it’s getting K-12 students involved, if it’s an introductory bootcamp or if it’s upskilling with advanced technologies—we need all of it and we need it fast,” he urged. “We gave our knowhow and our facilities away. We need to train people and get the knowhow back.”Ready to spark your future in metal? Register for our free online training then visit our events page to attend the next METAL bootcamp near you.

From Workshops to Workforce: UT Knoxville Forges the Future of Manufacturing in Tennessee

The first time Stephen Sheriff cast metal – a replica of the Wizard of Oz’s Tin Man – in front of an auditorium of elementary school students, he was hooked. Now, alongside his colleagues at the University of Tennessee, Knoxville (UTK), he’s determined to give students and job seekers exciting, in-person forging experiences.

Sheriff, who’s an engineer and research associate with the Fiber Composites Manufacturing Facility at Innovation South, is part of a team of almost 30 UTK staff and students who are bringing metalcasting to communities in East Tennessee.

In partnership with METAL, a program led by IACMI – The Composites Institute®, with funding from the Department of Defense’s Industrial Base Analysis and Sustainment (IBAS) Program, UTK has hosted four bootcamps for adults interested in metalcasting and 20 K-12 workshops. Both bootcamps and workshops cover metalcasting basics, including techniques for sand and investment casting. But now forging is becoming just as important to UTK’s education programs.

Forging, the art of blacksmiths and swordmakers, is the process of re-shaping metal using extreme pressure to form a high-strength tool. Unlike casting, where metal is melted down, poured and cooled to become a new creation, a forger hammers, presses, or rolls solid metal into shape. Most of the time, forgers heat the metal to make it more pliable, but not always. A metal part can be both cast and then forged to completion—and both processes are critical to modern manufacturing.

Today, there are about 3,000 stamping and forging companies in the U.S., but this number is declining. More than 240 forging plants closed and 21,000 jobs were eliminated as manufacturing left the U.S. However, the importance of forging is only growing for industry innovation and national security. Forging is necessary to produce critical parts in automotive, transportation, aerospace, energy and defense industries—from hand tools, hooks and chains to navy ships and fighter jets.

“When people think of forging, they think of Forged in Fire or making anvils, knives and horseshoes—that sort of thing,” Sheriff explained. “We’re exposing students to the differences between cast and forged parts and how you’re affected by them every day.”

New Irons In the Fire

Sheriff loves the spark he sees in students when they learn how metal can be transformed. This spring, he awed students at Seymour Primary School with a live sand casting demonstration, bringing one of their favorite characters to life at the school’s annual Book Bash.

Now, as UTK plans to roll out a new K-12 blacksmithing workshop, Sheriff is ready to create more moments that spark curiosity for forging.

“Seeing kids light up about what we’re doing is great,” he said. “When students get that metal part from whatever pattern they picked in their hands, and say, ‘This is really cool, I want to learn how to do this,’ it turns into a career or a hobby.”

Sheriff’s team recently tested the blacksmithing workshop’s new curriculum, which will include lessons on how to shape metal and use a forging press. Middle and high school students will have the opportunity to practice heating and flattening steel with an anvil before stamping the puck with a design.

One of the most important goals for Sheriff is helping students overcome their fear of working with red-hot metal.

“A lot of people are very intimidated when you hand them a piece of metal that’s glowing orange,” he said. “Some students might have experience with shop safety, but when you get students that aren’t involved with those types of activities, you need more time with them.”

Sheriff said clay forging will be one activity offered to help students practice without feeling the heat. Polymer modeling clay moves similarly to hot metal, Sheriff explained. With a palm-sized clay cube, students will use a plastic ballpoint hammer to draw the shape out and then stamp it with UTK’s “Power T” before baking it into a finished forging.

“I’m looking forward to getting students involved,” Sheriff said. “I think it’s going to be a lot of fun.”

Soon, UTK’s blacksmithing workshop will be available to schools across East Tennessee.

The university is also adding an introduction to forging to their free week-long bootcamps. UTK’s bootcamps, hosted in partnership with METAL, offer college students, professionals and career seekers a rare, hands-on opportunity to learn about metallurgy—from designing 3D molds, to melting, pouring and casting metal, to now forging a finished product.

Dustin Gilmer, an assistant professor in materials science and engineering at UTK who helps lead the bootcamps, believes forging skills will better prepare tomorrow’s workforce.

“We were up and running really quickly with casting, but forging is a little bit more specialized,” Gilmer said. Through partnerships with METAL, Pennsylvania State University, and The Ohio State University, UTK is developing a forging curriculum for bootcamp participants who see a future for themselves in manufacturing.

“We’re looking for people who think they have a career in this industry, and we’re trying to get them ready to enter the workforce,” Gilmer said. “That’s the goal of the bootcamps.”

Gilmer and his team plan to incorporate forging lessons and hands-on learning into UTK’s December bootcamp.

Forging Community

Beyond skills training, Gilmer and Sheriff are focused on connecting students and bootcamp participants to the forging community.

“We’ve lost a lot of this type of manufacturing in the U.S.,” Sheriff said. “We haven’t refreshed our workforce, and as foundry employees retire, there’s not many people coming up behind them learning the craft.”

The good news is, more than 3.8 million U.S. jobs will be there for metalworkers, engineers and manufacturing professionals who are ready to make an impact in the next decade. Gilmer said he’s been surprised by the number of metallurgical opportunities and support he’s found in Tennessee.

“When we first started our programs, I would’ve said we do not have a good metalcasting ecosystem. Since then, I have been proven wrong,” Gilmer said. “Having people champion us at the local level is why we’re so successful.”

For UTK’s team, the future of manufacturing starts with auditoriums of wide-eyed students and foundries where eager learners can discover the magic of metallurgy.

“The first time you see somebody pouring molten metal, it’s an experience,” Gilmer said. “It’s something you don’t usually forget.”

Ready to forge your future? Register for our free online training then visit our events page to attend the next METAL bootcamp or workshop near you.

Bring Your Best: Wisconsin Aluminum Foundry Pushes Metal Workers to Their Fullest Potential

Wisconsin Aluminum Foundry has earned a reputation for forging aluminum, bronze and brass castings that meet rigorous, high-quality standards of excellence—and the same can be said for the foundry’s metal workers.

With almost 1,000 team members across the midwest, Wisconsin Aluminum Foundry (WAF) supports critical manufacturing needs in the U.S. defense, agriculture, medical and automotive industries. Every employee, from intern to executive, aligns goals and performance with the foundry’s core values: “bring your best, engage to succeed together, pursue potential and invest in our future.” To WAF’s Vice President of Human Resources Michelle Szymik, investing in the future means equipping metal workers and apprentices with the skills to move the industry – and our nation – forward.

“We have to educate people about how important metalcasting is to our infrastructure and to sustaining our military,” Szymik said. “If we can’t get more people to come in and get trained and interested, that’s at risk.”

But to make better training opportunities possible at WAF, Szymik needed more resources and funding.

“There isn’t a lot of structured training in the foundry. You have to rely on your tenured employees to train new people who may have never even walked into a manufacturing environment before,” she explained.

It wasn’t until the AFS Leadership Summit 2024 that Szymik discovered Jobs for the Future (JFF)—and the solution to her problem.

In partnership with METAL, led by IACMI – the Composites Institute and supported by the Department of Defense’s IBAS program, JFF helps metals manufacturers overcome industry talent shortages with financial support and assistance in designing and implementing an apprenticeship or other work-based learning program. With the goal of growing the casting, forging, and plate rolling workforce, JFF provides manufacturers up to $24,000 per year for training equipment and services. So far, the organization has engaged more than 150 metal companies across the country and funded learning programs for nearly 77 participants—from maintenance technicians and machinists, to moldmakers and casters.

Mark Genua, director of solutions design and delivery at JFF, believes apprenticeships and other work-based learning programs provide a custom, structured approach to train highly skilled metal workers. But the expense of facilitating these programs isn’t always affordable for manufacturers.

“Like any training, there are costs associated with program implementation and operation,” Genua said. “We’re helping companies offset the costs and even enhance their programs with cutting-edge training, new equipment and participant support.”

Szymik couldn’t wait to get started.

Casting the Future of Metal

Apprenticeships and work-based learning is critical during a time when the U.S. casting and forging industry urgently needs thousands more skilled workers. But with the right resources, apprenticeships can result in 90% employment retention. Today, there’s 27% more apprentices in advanced manufacturing than in 2024, thanks to partners like JFF and METAL.

This support was exactly what WAF needed to build, expand, and strengthen its work-based learning programs.

Szymik has a brimming wish list for how she’d like to use JFF’s funding—from finishing training for new employees to pattern maker apprenticeships and on-the-job learning for quality control team members and maintenance techs. For now, she plans to put the funds toward WAF’s new trainer position and offsetting training program costs.

Team trainer Shane Chase was one of the best finishing sanders and mentors on the production line. Now, he’s teaching the next generation of quality metal workers and growing his career.

“Something I noticed over the years is just because you are good at your job doesn’t mean you would be a good trainer,” Chase said. “It’s so important we have the training program because not everyone has the patience and the ability to work with anyone.”

Chase added that he sees this role as a stepping stone toward becoming a supervisor or manager. “When that day comes I hope I can find someone like myself to pass the reins to.”

WAF will be able to put their funding toward Chase’s salary as well as new supplies, such as sander belts, for the training program. But Szymik said this is only the beginning for WAF’s training and apprenticeship development.

Forging Metal’s Finest

Szymik’s dream is to fund career growth and education in the metal industry all the way through the funnel—from high school to first jobs and beyond. Most of all, she wants to show people what being a metal worker has to offer.

“We’re teaching people a career when they walk in the door. It’s not just a job,” Szymik said. “We want to show people you can build a rewarding career and support your family, and it’s work that’s needed.”

She recommends that all metalcasting companies apply to partner with JFF and METAL so together we can forge a resilient metal workforce.

“I talk to so many smaller companies that don’t have a budget for training,” she said. “I tell them, tap into this. You have the opportunity and it’s so easy to apply and get your metal workers the training they need. This funding has been huge for us.”

Ready to fuel your foundry’s future? Apply for JFF’s apprenticeship incentive program here.

Learn more about youth apprenticeships in a recent webinar featuring Szymik.

Ready for Anything: Army Engineer Sydney Parks Finds New Strength at METAL Bootcamp

When Sydney Parks first stepped onto Tennessee Tech University’s campus, she planned to be a nurse—and she had no idea about the school’s foundry. This summer, almost a decade later, Parks returned as an Army technical engineer to become field-ready in a new essential skill: metalcasting.

Parks, 29, never quite knew where her career would take her. After high school, she tried everything from the food service industry to manufacturing management to email marketing and website building. But Parks was always certain of one thing: she wanted to have as many new experiences as possible. The Army felt like her perfect opportunity.

She decided to pause her nursing degree and soon pursued training in places like Cuba and Kuwait. “I thought it would be a good time to absorb as many of those experiences as I could,” she said.

The Army also led Parks to her passion for engineering. She first became curious about how rotors, gears and other parts work together as a teen repairing her first car. But joining the military reignited her “find a fix” attitude.

“The military teaches you a lot of resiliency,” Parks said. “Even though I’m a technical engineer, if the vehicle I’m associated with needs maintenance, I have to learn how to do that. I believe that carries into my life and how I solve problems.”

In her career, Parks has led engineering teams for critical products and buildings, draining assessments and survey work across the Middle East. After returning home from her first deployment this year, Parks was eager to learn more skills that could be an asset in the field.

That’s when she discovered METAL’s metalcasting bootcamp at Tennessee Tech University. Led by IACMI – The Composites Institute®, with funding from the Department of Defense’s Industrial Base Analysis and Sustainment (IBAS) Program, METAL strengthens the U.S. metal manufacturing workforce. Before diving into the on-campus experience, she completed METAL’s free, self-paced online training. The course is designed to support bootcamp readiness, but it’s also available on its own for anyone eager to explore metalcasting. When she realized the bootcamp was hands-on and so close to home, she jumped in—boots first.

“I wanted to go into it full force,” Parks mused, adding that she was especially interested in the lessons on CAD software. “Being from a military engineering background, I find it very exciting to learn as much about it as I can.”

“I felt like a sponge”

Through METAL’s free week-long bootcamps, participants from diverse education and career backgrounds have a unique, hands-on opportunity to learn metalcasting from professional metallurgists. The bootcamps are not just for college students, but for anyone who’s interested in metal manufacturing, said Dr. Ismail Fidan, a professor of manufacturing and engineering technology at Tennessee Tech University.

“As an instructor, it makes me excited because most schools teach metalcasting, but they teach it through the book and hands-on is limited,” Dr. Fidan explained. “These opportunities through the top universities give people their first training.”

Through METAL’s bootcamps, Dr. Fidan has taught engineering students, professors, job seekers, retirees and service members like Parks skills that advance the entire metal industry.

“The nation is in a transformation to smart manufacturing. You get a product with a high volume, high quality, and you get a product that you want,” Dr. Fidan said. Smart manufacturing allows metal manufacturers to have more control of the production process using automation, robotics, AI and machine learning and other smart technologies. But the U.S. workforce needs more metal workers and engineers who can bring metalcasting to the 21st century, he said.

Parks was up to the casting and forging challenge. From welding and fabrication equipment to furnaces that liquify metal, she couldn’t believe what was possible in Tennessee Tech’s foundry.

“I felt like a sponge,” Parks said. “There was so much to learn and it’s a lot to take in, but the more I listened, the more it all made sense. The instructors and the assistants were really good at breaking it down to where I could understand everything at my level.”

After the first day, Parks invited her boyfriend Nicholas Bartik to attend the rest of the bootcamp with her. Bartik, who’s been an automotive technician for eight years, recently made the decision to start his own auto parts business. Parks thought the bootcamp could help Bartik better understand processes for designing and casting car parts, and he agreed.

“There is a lot of cool tech in the automotive industry,” Bartik said. “I’ve met engineers in the field who are using casting, 3D modeling and printing and different forging processes to produce components that improve engine performance. I want to integrate this type of engineering into my new company.”

Together, Parks, Bartik and the bootcamp’s participants each had the rare opportunity to sand-cast a creation of their own.

“We have hundreds of patterns to choose from,” Dr. Fidan said, adding that participants get to execute every step of the sand casting process—from picking a mold to pouring molten aluminum to learning about high quality testing. “They make it and grind it, polish it and they take it home for themselves. They have all this experience from the first day of the bootcamp to the last.”

Besides forging her own piece of art – a starfish – Parks was most fired up about visiting a professional foundry.

Casting in Action

On the last day, the casters-in-training spent the morning at Triple C Machine in Livingston, Tennessee. Triple C Machine specializes in cold forging operations and other tools used for precise metal cutting and pressing, as well as production machining, metal stamping and MIG and TIG welding. Parks said the demonstrations gave her the basic understanding and inspiration to make her own custom creations.

“It’s really cool knowing how to go from zero to a completed part,” she said.

As Parks looks for her next civilian opportunity, she’s excited to try more workshops where she can make connections and learn skills that help her at home and while protecting the nation. Thanks to METAL, Parks feels more prepared to face challenges in her next deployment—from casting critical parts to supporting mobile welding services for the Department of Defense.

“Now I can apply what I learned to help myself or my peers in certain situations,” Parks said.

She would love to bring more Army technical engineers to future bootcamps. But she recommends the experience to anyone, even for the pure joy of learning something new.

“Forging and casting have become forgotten. People don’t realize what it takes to create the items we use everyday,” she said. “I’m very appreciative of this opportunity. It’s available to anyone who’s willing to take the time to sit and learn.”

Ready to cast a new future—together? Register for our free online training then visit our events page to attend the next METAL bootcamp near you.

Casting Confidence: How Victoria Rambo Ignited Her Career in Metal with FEF

After starting college during the COVID-19 pandemic, Victoria Rambo began to doubt her future as an engineer. But everything changed when she discovered Virginia Tech’s foundry and resources through the Foundry Educational Foundation (FEF) and METAL. The partnership, funded by the Industrial Base Analysis and Sustainment office within the Department of Defense, accelerates the development of a skilled workforce through hands-on training and internship opportunities. Rambo quickly molded her doubt into a promising future in metal.

One year after graduating, Rambo, 23, is an associate metallurgist at Carpenter Technology Corporation who focuses on alloy research and development. The enthusiasm she stoked in Virginia Tech’s foundry has led her to creating replica missile fins for the National Museum of the Marine Corps, presenting at the American Foundry Society (AFS) national conference and being featured in the book Women in Steel Volume II.

If you told Rambo about her current job as a freshman, she wouldn’t have believed this career path was possible.

“When I started college during COVID, I was thrown into online classes. I was struggling to make connections with professors and with other students,” she explained. “I started with a low GPA and thought, is engineering really worth it?”

By her sophomore year, a friend recommended Rambo visit Virginia Tech’s foundry, one of 20 FEF-certified university foundries in the country. She met FEF Key Professor Alan Druschitz and was eager to learn more about what the metal industry had to offer. Druschitz’s mentorship was exactly what Rambo needed to spark a sense of purpose—and her comeback to engineering.

“He was one of the first professors I connected with who cared about the student to teacher relationship,” she said. Soon, Rambo’s confidence lifted, her academic performance improved, and the foundry became her second home.

Igniting a Future in Metalcasting

Rambo’s first stint in engineering was in high school. Both of her parents are mechanical engineers with the Department of Defense, and she planned to follow in their footsteps. She went to a vocational high school where she took classes like drafting and began to explore robotics competitions and STEM programs. Her first internship was at Aberdeen Proving Ground with the Army Educational Outreach Program working on weather-detection sensors for drones.

What drew her toward a degree in material science and engineering was bringing concepts and designs to life off the paper. In the foundry, Rambo used fire and metal to do just that.

“I was basically living there by my senior year,” she joked, as she became enamored with learning the casting process. In her classes, she studied the basics—how to make molds, steps to pouring molten metal and when to use an induction or resistance furnace. Before long, she was ready to apply these skills to innovative research and mentoring other metallurgy students.

Through research assistantships funded by FEF and METAL, Rambo was able to support graduate students’ metalcasting projects and soon she was leading cutting-edge research of her own.

Together, Drushitz and Rambo launched first-time research in the properties of ductile iron, which is often used in pipes, automotive parts and agricultural equipment that can withstand fluctuating temperatures. Thanks to FEF’s funding, Rambo was able to experiment with the iron for more than a year, exploring how to make the production process less expensive with manganese and aluminum instead of nickel.

This research is ongoing at Virginia Tech’s foundry, but Rambo had the opportunity to present her preliminary findings at the American Foundry Society’s 2024 Metalcasting Congress. She said opportunities like this one provided her with the skills to be successful in her career.

“It helped me with my professional development and the technical knowledge when I was applying for the job that I have now,” Rambo said. “With the conferences, you’re also developing your soft skills, communicating and building your social network and meeting students from other universities. I think that is so important.”

Drushitz continued to mentor Rambo, encouraging her to apply to internships with the Swedish steel company SSAB and for scholarships with FEF and the American Institute for Steel and Technology. In 2023, she received FEF’s Keith Dwight Millis Scholarship for students interested in the advancement of ductile iron.

Rambo said having a great mentor is even more important for women in the metal industry. Less than one-third of employees in manufacturing are women, according to a report from the Institute for Women’s Policy Research.

“Drushitz was always there to make sure my voice was heard,” she added. “I don’t think I would’ve been able to accomplish what I have without him.”

Molding an Industry Leader

By her senior year, Rambo served as Virginia Tech’s AFS President, taught three classes in the metalcasting program and had six job offers before she graduated. Most engineering students struggle to excel after a low GPA, Druschitz said, but Rambo’s involvement with the foundry gave her the spark she needed to thrive.

“Victoria was highly recruited by foundries and the steel industry,” Druschitz added. “She started to get involved with the Women in Steel conferences and those are great for support with people who will say, ‘you can do it.’”

In addition to her research experience, Rambo believes her expertise in the MAGMA casting design software helped her stand out to potential employers. She learned how to use the industry program through an FEF student training session and later earned a level 1 certification so she could teach MAGMA to other students. Not only was the software essential in student casting competitions, Rambo said it’s a core skill manufacturers are looking for.

“I think that shows how much FEF is trying to make metallurgy and metalcasting innovative and part of the future,” she said. Rambo added that there’s often a misconception with students that metallurgy is an “old science,” but new technology is always pushing the industry forward.

Sometimes Rambo still can’t believe the metalcasting and leadership experience she gained while earning her undergraduate degree. She’s thankful to FEF and METAL for the financial opportunities and support that helped mold her career.

“FEF wants to support the future generation of students coming into the industry,” Rambo said. “If you fall in love with metalcasting, give it your all because the opportunities will be there. The connections you make with professors and students will be your biggest support along the way.”

To learn more about FEF’s METAL internship opportunities, email nbacik@fefinc.org.

To learn more about METAL, including apprenticeships and online training, visit metalforamerica.org or fill out our contact form.

Fast Track to Success: FerroWorks Trains Next Generation of Metal Workers

For more than 150 years, FerroWorks’ foundries have powered trains and railroads in America. Now, the steel company is keeping manufacturing in the U.S. on track by training the next generation of highly skilled metal workers.

FerroWorks, which manages McConway & Torley, Standard Forged Products, Kutztown Foundry and Machining, and McKees Rocks Forgings in Pennsylvania, is known for its excellence in casting couplers, knuckles, and yokes—all parts that connect train cars together. The U.S. rail system transports 1.5 billion tons of goods and more than 28 million passengers each year, and keeps growing. Between 2022 and 2026, $66 billion will go toward improving railways and expanding train services, according to the American Society of Civil Engineers. In addition to casting critical train parts, FerroWorks is forging the growth and development of its employees. With funding from METAL and its partner Jobs for the Future (JFF), which supports companies in the development of high-quality apprenticeship programs, FerroWorks is training more metallurgists to keep up with the industry’s high-speed growth.

Kara Keith, a human resources generalist at FerroWorks, leads internal enrollment for the Industrial Manufacturing Technician (IMT) program—one of the pillar continuing education programs FerroWorks offers.

The 18-month apprenticeship program is hosted by the Community College of Allegheny County (CCAC) in Pittsburgh, Pennsylvania. Once a week, instructors from CCAC offer on-site training to a select cohort of FerroWorks’ team members. The classes range from industry topics like blueprint reading, mechanical and electrical systems, and pneumatics to leadership training and communication skills. Keith said the program is essential to providing employees with a well-rounded understanding of industrial manufacturing.

“Transferring knowledge is something that we struggle with in this industry,” she said. “This program makes our employees feel like they’ve been invested in and gives them a chance to learn more about other departments that they wouldn’t get to explore in their day-to-day roles.”

So far, 12 FerroWorks employees have graduated from the IMT program. This year, JFF will help sponsor training for six FerroWorks team members with its apprenticeship/work-based learning incentive funding, in partnership with METAL.

A Freight of Opportunities

The U.S. casting and forging industry faces a pressing need for 122,000 skilled professionals by 2028 as workers retire and industry growth surges. In addition to a shortage of skilled metal workers, about 60% of manufacturers said attracting and retaining employees is a top challenge in a National Association of Manufacturers survey.

Through METAL, led by IACMI – the Composites Institute and supported by the Department of Defense’s IBAS program, JFF has helped seven companies to date build, expand and sustain work-based learning programs, including apprenticeships. These programs allow manufacturers to improve training and retention in casting and forging roles—while offsetting the cost. JFF’s incentive funding can be applied to in-person or online learning programs, training equipment and trainer costs, curriculum development, program design and implementation, and support services for apprentices.

“America’s casting and forging industry is essential to our country’s national security, infrastructure and other industries,” said Mark Genua, director of solutions design and delivery at JFF. “So we need a robust, well-trained workforce to fill these much-needed roles.”

For Keith, applying to JFF’s incentive funding was an easy decision and process. The funding FerroWorks receives will go toward tuition for CCAC’s IMT courses—and educating the company’s future leaders.

FerroWorks’ Rob Cain earned his IMT apprenticeship certificate before becoming a production operations supervisor. Cain started with the company as a grinder and said the apprenticeship program gave him the confidence to take the next step in his career.

“I already had the technical skills, but the IMT training gave me a more well-rounded understanding of the bigger picture, like how different systems and processes come together,” Cain said. “I still use what I learned in the program every day in my leadership role.”

IMT’s apprenticeship program is a nationally recognized certification that advances participants’ careers wherever they work in manufacturing. For FerroWorks, programs like IMT help the steel company reach production and retention goals, but Keith said the greatest benefit is employee development.

“At the end of the day, the more leaders we can grow and grow people who can teach others, the more knowledge sharing and learning takes place,” Keith said. “We’re ultimately fostering a more skilled, versatile and engaged workforce.”

Ready to forge a stronger manufacturing workforce? Apply for JFF’s apprenticeship incentive program here.

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