When Dr. Samantha Trzinski accepted the challenge to build a new forging class, she entered unfamiliar territory. Her career up to that point had been in education, not metallurgy. But by pairing her gift for inspiring students with the guidance of world-renowned metallurgists, Trzinski designed a program that’s preparing the next generation of America’s metal forgers.
In partnership with METAL, the U.S. National Science Foundation HAMMER Engineering Research Center (NSF HAMMER-ERC) set out to develop a self-paced course that introduces students and career seekers to the science and possibilities of forging. NSF HAMMER-ERC develops modern approaches to manufacturing with advanced, autonomous technologies like AI to streamline production.
But at the heart of American manufacturing is a workforce that’s trained and ready for tomorrow’s challenges.
Forging, or reshaping solid metal using extreme pressure, is a craft that’s still critical for producing metal parts and tools. Industries like automotive, aerospace and national defense rely on this age-old trade to build everything from handheld wrenches and heavy-duty axles to aircraft engine parts, missile casings, and the steel that strengthens Navy ships and fighter jets.
“What’s so exciting about forging is you’re making the essential components for everyday life,” said Trzinski, who’s the director of education outreach and workforce development at HAMMER-ERC. “That’s how we make the parts that go into cars, planes, and the barebones of buildings. Forging builds things that keep the world running.”
However, the U.S. workforce is at a pivotal moment. As millions of Baby Boomers retire, an entire generation of metal workers has laid down their hammers and stepped away from the forging press—leaving behind a widening gap in skills and experience.
By 2033, almost 2 million manufacturing jobs could be available in the U.S., without enough skilled workers to sustain the nation’s supply chain and defense needs.
“There are times in history when a brush fire wipes everything out and you rebuild. We’re almost in that place in casting and forging where we’re starting over,” explained Dr. Glenn Daehn, director of NSF HAMMER-ERC and Mars G. Fontana professor of metallurgy at The Ohio State University. “The future is bright, but we need to make smart decisions to get there.”
Organizations like NSF HAMMER-ERC and METAL are rebuilding America’s manufacturing resilience. Led by IACMI – The Composites Institute®, with funding from the Department of War’s IBAS Program, METAL is accelerating the development of a talented, adaptive workforce through K-12 workshops, in-person bootcamps and apprenticeship training.
Before sparking potential in the forge, Trzinski recommends exploring the fundamentals of metallurgy with METAL’s online courses. The forging course is the newest addition to METAL’s library of free, self-paced casting and forging resources for all education and industry levels.
“We wanted to make the class accessible to someone with no background in metallurgy, and I think we’ve done that,” said Daehn. “But for somebody who has been around metals and forging, there’s still a lot you can learn from the course.”
Enrolling in METAL’s courses is exactly how Trzinski prepared to collaborate with global forging experts—what she calls her “trial by fire” in metal.
Trial by Fire
Trzinski and Daehn partnered with Dr. Erman Tekkaya of the University of Dortmund’s Institute of Forming Technology and Lightweight Components, Dr. Alex Bandar, director of the Innovation Ecosystem for NSF HAMMER-ERC, and Dr. Stephen Niezgoda from The Ohio State University to engineer leading-edge material for forging students.
The result? A course built to ignite manufacturing transformation.
Through the class, learners are introduced to the foundations of materials science before exploring advanced topics like hot, warm, and cold forging, tool and die design, and types of presses. Each lesson includes lectures, slide decks, quizzes, and recommended readings and videos for discovery at your own pace.
The course strikes upskilling for industry professionals through modules on Industry 4.0 and the Future of Forging. Industry 4.0 covers how sensors and smart systems optimize production and support predictive maintenance. Meanwhile, the Future of Forging explores digital simulation and FEM tools that help engineers calculate press loads to forge parts safely without overloading equipment.
Fortifying the metal industry with modern tech will sustain American manufacturing—and drive innovation forward, Daehn said. “Most forging houses have remarkably little data or real-time feedback. There are a lot of opportunities we want to make people aware of.”
For example, tools like accelerometers and strain gauges can be attached to microphones on equipment to detect early signs of dysfunction. This allows manufacturers to perform preventative maintenance and avoid costly repairs.
“There’s a lot of room for innovation,” Daehn added. “I’m hoping we can spark ideas and give people a foundation to find new solutions for long-term problems.”
But driving the metal industry forward takes more than smart technology—it requires people who are curious, ambitious and ready to lead.
“As we’re coming up with technological innovations, we’re going to need a new skilled workforce that knows how to adapt and be innovative,” Trzinski said. “A lot of times, people think about manufacturing as dark and dirty factory jobs with long hours and little pay, but that’s not what it is anymore.”
Forging is For Everyone
From hands-on production to quality control, engineering and management, forging opens doors to dozens of essential manufacturing roles. Most metal workers who operate forging machines in the U.S. make about $47,000 a year or more, with potential for fast growth.
If there’s one thing Trzinski wants people to learn from the forging course, it’s that careers in metal are exciting, engaging and for everyone.
“When I work with students, I try to emphasize that whatever you enjoy studying or doing, there’s a place in manufacturing where you’ll fit. Every skill is necessary,” she pointed out. “It’s just figuring out how these skills work together to create whatever it is we need to create.”
Trzinski—who holds a PhD in English literature—is proof of what’s possible in metal when determination meets opportunity. She said if she can complete a forging course with no metallurgy experience, anyone can.
“The class is for anyone who’s willing to learn,” Trzinski said. “If you don’t have a forging or engineering background, your idea of manufacturing is probably so different from what it truly is—and right now, it’s an incredibly exciting place to be.”
Ready to forge a stronger tomorrow, today? Register for our free online training, then visit our events page to attend the next METAL bootcamp near you.