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.

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.

Casting the Future: Ianto Woolridge’s Journey into Metalcasting with FEF

Metallurgical Engineering Trades Apprenticeship & Learning (METAL) partners with the Foundry Educational Foundation (FEF) to help build the next generation of talent in U.S. manufacturing.

Established in 1947, FEF is the liaison between students, educators and industry leaders, ensuring young engineering talent enters the metalcasting industry. Today, it continues that mission by supporting scholarships, engineering programs and internships that shape the next generation of professionals in the field.

As part of this partnership, FEF has placed 24 interns from 10 universities in its first program phase and secured multiple industry partners to develop 10 more internships.

FEF Interns work on real-world projects, assist with student outreach and gain critical networking opportunities that help shape their careers.

Meet Ianto Woolridge

Through our collaboration with FEF, METAL supports students like Ianto Woolridge, a freshman at Virginia Tech majoring in Materials Science and Engineering.

As part of FEF’s internship placement program, FEF placed Ianto at Virginia Tech as a foundry intern specializing in investment casting using 3D-printed expendable molds. His regular duties include setting up gating, creating molds around cast patterns and sintering molds under the direction of Virginia Tech foundry director Dr. Alan P. Druschitz.

Woolridge joined FEF in the Fall of 2024 and has since gained valuable insights and direction for his future career. Here’s what he said about how his FEF program experience has shaped his academic and professional goals.

Q: Tell us about your experience in metalcasting since joining the FEF program.

A: The FEF internship was my first real exposure to metalcasting and it’s been such a valuable experience. I joined the program in the fall of my freshman year. At that time, I had no idea what to expect. I knew I was interested in materials science, but I hadn’t explored the practical side of how those materials are used in manufacturing. Getting into the foundry for the first time was eye-opening. I saw firsthand how raw materials are transformed into usable products and that hands-on experience helped me understand the purpose behind what I’m learning in class. It was a huge shift from theory to practice and sparked a genuine interest in metalcasting.

Q: What essential skills have you learned from your time in the university foundry lab?

A: One of the biggest things I’ve developed is my problem-solving ability, especially under real-world conditions. In the foundry, things don’t always go according to plan. Whether it’s issues with temperature control, molds, or unexpected results in the casting process, I learned how to stay calm and work through challenges methodically. I also developed better communication skills. I leaned heavily on seniors in the foundry who had more experience and they were incredibly supportive. Collaborating with them taught me to ask the right questions, learn from feedback and troubleshoot effectively. I know I’ll take these skills with me into any engineering or professional setting.

Q: How do you see your metalcasting experiences influencing your career path?

A: When I first came to Virginia Tech, my plan was straightforward: get a degree, go to graduate school, earn a PhD and work in a research lab. But the FEF experience shifted my perspective. Working in the foundry made me realize that I prefer hands-on, outdoor work where I can physically interact with materials and processes. I enjoy the energy of the foundry, the teamwork and the tangible outcomes. While I still value academic research, I now see myself pursuing a more applied role in the industry—something that blends engineering with real-time problem-solving and production.

Examples of Ianto Woolridge’s work as part of the Virgina Tech FEF Program

Q: In what ways has FEF supported your academic and industry experiences?

A: FEF has made a significant impact on both my education and my confidence as a student. Because I had early exposure to real casting and manufacturing techniques, I’ve felt more prepared and less intimidated by my coursework – especially in classes like manufacturing, where we’re expected to understand casting principles. That’s been a game changer for me. It’s one thing to study manufacturing, but it’s another to see and do it for yourself. FEF allowed me to apply what I’m learning and to connect the dots between theory and practice.

Q: What message would you share with supporters of FEF who help make these opportunities possible?

A: I can’t thank FEF and its supporters enough. Without the scholarship and the opportunity to get involved early in the foundry, I probably wouldn’t have discovered how much I enjoy this type of work. It’s not just about the financial support – though that certainly helps – it’s about being given a space to learn and explore. Because of this program, I’ve explored options for a future career after graduation. I hope donors and industry partners continue to invest in FEF because their impact on students like me is life-changing.

Q: What would you say to other students or the general public who may not be aware of opportunities in metalcasting or manufacturing?

A: There’s a gap in awareness. Many students go into engineering just thinking about high-paying jobs, but they often overlook careers in metallurgy or manufacturing. These fields are essential to the U.S. economy but don’t get the visibility they deserve. Programs like FEF help change that by exposing students to what these careers look like. They show us that hands-on, high-technology work in these industries can be just as impactful and rewarding as more traditional engineering paths.

Learn more about FEF’s programs and its mission here: https://www.fefinc.org/