Tag Archives: Metal Workers

Four Generations of Excellence: How HFW Industries Inc. Strengthens American Metal Manufacturing

Harold Watson started HFW Industries Incorporated in 1947 in a two car garage. 

World War II had ended only two years prior, and the United States emerged as a global manufacturing powerhouse. During the war, American manufacturers helped lead the Allies to victory — producing 297,000 aircraft, 193,000 artillery pieces, 86,000 tanks, and two million Army trucks at a scale the world had never seen before. When the war ended, that industrial momentum quickly shifted back to automobiles, infrastructure, and consumer manufacturing. 

Harold, a foundry maintenance superintendent, was responsible for keeping machines the U.S. troops and metal manufacturers relied on running smoothly. That’s what he was doing when he found an innovative new product, the metal spray gun, and inspiration sparked. Could the spray gun help industrial equipment last longer and reduce time spent waiting on repairs?

Harold bet it could and started a business he believed would reinforce America’s strength as the greatest manufacturer in the world. He was right.

Today, HFW Industries Inc. is a leader in high-performance surface enhancements and manufacturing technologies, built on the same spirit of innovation and industrial excellence that defined America’s manufacturing strength during WWII. 

Almost 80 years later, Harold’s legacy lives on through his great-grandson, Jack Watson. At 26 years old, Watson is a fourth-generation manufacturer and business development manager empowering HFW Industries Inc.’s mission to serve U.S. defense, energy, and other critical industries people depend on every day. 

Watson recently attended a METAL bootcamp to connect with other manufacturing leaders and learn the science behind metalcasting and forging. For manufacturers like HFW Industries, METAL’s training opportunities share foundational metallurgical knowledge while introducing more people to the careers and technologies driving America’s metal industry forward. 

Here’s what Watson said about his METAL experience, thermal spray innovation, and why he believes American manufacturing still offers enormous opportunity for the next generation. 

Hear Jack’s story:

How did HFW Industries Inc. start?

HFW was started by my great-grandfather, Harold, coming out of World War II. During the war, he worked at a foundry in Buffalo, New York. It’s funny that as part of the METAL bootcamp we’re talking about and exploring foundries and that’s where we started. My great-grandfather worked as a maintenance superintendent, repairing equipment, sending it out to be rebuilt or made new. In that role, he came across this new technology at the time, the metal spray gun, and it allowed him to repair his own parts by spraying metal back onto them.

It really was additive manufacturing in the early days. Now, when you say additive manufacturing everyone thinks of 3D printing, but thermal spray was one of the early forms. My great-grandfather was enamored with it. He could immediately see the benefits of being able to repair his own equipment, not having to send it out — saving costs, money and time. That’s a big one, being able to repair equipment in-house and not sending it out to someone to get it back in a couple weeks. 

So Harold was excited. He went to his boss and tried to make a case for the metal spray gun. As the story goes, his boss wasn’t interested and said, “I think we’re okay” 

In classic Watson family stubbornness, he said, “If you’re not going to buy the gun, I will.” 

The rest is history. Harold bought one of the first commercially available spray guns, and today thermal spray is core to the metalworking industry. My great-grandfather became a pioneer in the thermal spray industry and helped write a lot of the technical material about it. He was one of the first technical advisors for the American Welding Society’s standards for thermal spray. So my family and our business are deeply entrenched with the thermal spray community and how it started.

Jack Watson, left, fourth-generation U.S. manufacturer and thermal spray specialist learns how to pour a metalcasting for the first time during METAL’s Penn State, Behrend bootcamp.

Jack Watson, left, fourth-generation U.S. manufacturer and thermal spray specialist learns how to pour a metalcasting for the first time during METAL’s Penn State, Behrend bootcamp.

As a fourth-generation manufacturer, why did you attend METAL’s bootcamp?

Honestly, the biggest reason was the people. There are a lot of very like-minded people here that are facing similar problems, but who also see the massive opportunity in front of American manufacturing right now. Some of the best conversations happen outside the classroom — in the hallways, at dinner, during the tours — and a lot of times those conversations are just as impactful as the classroom sessions themselves. 

For me, attending METAL’s bootcamp was a no-brainer. It’s not like you’re just going somewhere to play golf, although I like that too. There’s a real purpose to this. You’re learning, you’re building relationships, and you’re around people who are passionate about manufacturing and solving really tough problems.

The other big piece for me was the actual subject matter around castings and forgings. At HFW, we work with castings, forgings, turbine shafts, compressor equipment and rolls going into chemical plants. Those are often the starting point for the work we do. Metallurgy is a huge part of our business, and while I knew a lot of the general background, I wanted to better understand what comes before our part of the process. The bootcamp honestly opened my eyes quite a bit, and I left with a lot of things I want to study further. 

I also think one of the biggest things METAL and programs like this provide is exposure. Most people just don’t know much about these industries or their opportunities. A lot of people still picture manufacturing as dirty steel mills and coal mines from the early 20th century, and that’s just not what manufacturing is today. There are a lot of really advanced, highly technical careers in this industry, and for somebody who enjoys niche manufacturing solutions and tough manufacturing problems, it’s a really exciting space to be in.

What are the challenges U.S. manufacturers face right now?

The easy answer is talent, and I don’t think there’s an easy solution. A big part of the challenge is changing the perception around the trades and helping people understand the opportunities that exist in manufacturing today, which is why programs like METAL’s bootcamp are so important. At the same time, these industries require extremely skilled people, and that level of expertise doesn’t happen overnight. In our world, it can take five to 10 years to really master the craft, especially in a specialized field like thermal spray. There just aren’t a lot of thermal spray technicians walking around on the street looking for jobs.

That’s why the focus has to be on training, patience, and long-term investment in people. Most of our thermal spray technicians are trained on the job because a lot of the work we do is so specialized that very few other companies are doing it. We invest heavily in teaching, building career paths, and creating an environment where people want to stay and grow long-term. There’s definitely a learning curve, and people are going to make mistakes along the way, but if you find great people who are willing to work hard, there’s a huge opportunity in manufacturing right now. I really believe it’s a generational opportunity for someone to build a strong career, do very well for themselves, and provide for their family.

Manufacturing entrepreneurs Zach Glabman, Jack Watson, and Daniel Scott Mitchell suit up for their first metal pour at Erie Bronze & Aluminum Co. during METAL’s Penn State, Behrend bootcamp.

Manufacturing entrepreneurs Zach Glabman, Jack Watson, and Daniel Scott Mitchell suit up for their first metal pour at Erie Bronze & Aluminum Co. during METAL’s Penn State, Behrend bootcamp.

What happens when U.S. manufacturers can’t find skilled workers?

When manufacturers can’t find skilled workers, you start seeing projects get delayed because there are only so many companies and people that can do highly specialized work. In some cases, there are very few vendors, if any, that can handle certain projects, and the ones that can, end up with backlogs that are months or even years out. That creates a tough dynamic for everybody. The manufacturers want to meet customer demand and expand capacity, and the customers buying that equipment obviously aren’t thrilled when lead times stretch out that far. 

We’ve seen outsourcing over time, but the bigger point is the opportunity is already here in the United States. We just need a lot more skilled tradespeople to actually meet that demand.

The reality is that the true skill in manufacturing comes through time and experience on the job. Right now our average tenure is around 10 years, and a lot of the real value comes from the people with decades of experience who have mastered their craft over time. We had some great veterans here with 30 and 40 years of experience who retired recently, and that’s hard knowledge to replace overnight. METAL is doing great work to expose people to manufacturing careers, but companies also need to step up and invest in training and retention. 

For students or people considering manufacturing careers, I’d just say give it a chance and be persistent. A lot of these careers are challenging, but the learning compounds over time, and when you move around jobs every year, it’s hard to build that depth of experience.

Start your career in metal today with METAL’s free online training.]

How can modern metal manufacturers build on America’s legacy of manufacturing excellence and innovation? 

There’s a lot of momentum around manufacturing right now, and I’m very enthusiastic about that. The only thing I’d push back on a little bit is when people use the term “reindustrialization,” because there are a lot of great manufacturers that have been here all along. Companies like ours have survived four generations because we’ve always been willing to innovate, try new things, and take on applications that other people were scared to attempt. That willingness to constantly improve and push ourselves is why we’re still here today. It’s easy for companies to rest on their laurels, especially after being around for a long time, but I think the real opportunity is in continuing to try difficult things, even knowing not all of them are going to work. The ones that do are the ones that build customers for life.

At the same time, there are so many small and midsize manufacturers across the country that desperately need people, are willing to pay well, and are great places to work. A lot of them have great people, a lot of flexibility, and huge opportunities for somebody who’s young and driven to come in, learn from men and women who have been doing this for decades, and build a career for themselves. 

I hear people say sometimes that there’s not as much upward mobility anymore or that the American dream is harder to achieve today. I disagree. I get to see every day the people who are still living proof that it exists. Manufacturing is still a great way to build a life for yourself and your family. There’s a huge opportunity for the next generation to step into these industries, learn the business, maybe eventually take over a company or start one of their own, and do very well while supporting their communities. That’s really my personal mission and why I’m so passionate about getting more people exposed to manufacturing. 

What is thermal spray and why is it important to modern manufacturing?

Thermal spray started as a pretty straightforward repair process. The easiest way to think about it is like brake pads on a car — the more you use them, the more they wear down. Industrial equipment works the same way. Over time, surfaces wear down, equipment gets damaged, and processes stop working the way they should. Thermal spray was first developed as a way to restore worn parts to like-new condition by spraying metal back onto them instead of replacing them entirely.

Over the last 80 years, thermal spray has evolved into something bigger. Today, it’s used not just to repair equipment, but to improve how equipment performs in really harsh environments. A lot of thermal spray coatings are designed to prevent extreme wear and corrosion or help equipment handle intense heat and thermal cycling. Think about an airplane engine or a gas turbine that goes from room temperature to more than 2,000 degrees and back again, over and over. Thermal spray coatings help protect those components and extend their lifespan.

What’s really interesting is how versatile the technology has become. Early thermal spray processes mostly used metal, but now manufacturers use all kinds of materials depending on the application — metal alloys, ceramics, and specialized coatings designed for very specific properties. Some coatings act as thermal barriers to protect equipment from heat, while others are used in electronics and semiconductor manufacturing because they can either conduct electricity or prevent conductivity. At the end of the day, the goal is usually the same: help equipment last longer, reduce downtime, and improve manufacturing performance.

Harold Watson, back, founder of HFW Industries Inc., fuses a thermal spray coating to a large metal shaft. HFW Industries still uses the same spray and fuse process today.

Harold Watson, back, founder of HFW Industries Inc., fuses a thermal spray coating to a large metal shaft. HFW Industries still uses the same spray and fuse process today.

How does thermal spray support critical U.S. industries?

At HFW, we’ve become specialists in not only thermal spray coatings, but in end-to-end industrial equipment restoration and wear prevention. Our team provides thermal spraying (HVOF, plasma and electric arc spraying), hardfacing, machining, precision finishing, and equipment assembly to national defense and critical industries, including:

U.S. Naval and Maritime

Over the course of HFW’s history, we’ve done quite a bit of work that’s tied to naval and maritime applications. Some of it has been directly for the Navy, and some of it supports the manufacturers making materials and systems that ultimately end up in defense and commercial shipbuilding. One of the stories that always gets talked about around here — and this was long before my time — was a project where the company actually sprayed Navy test equipment nose cones with gold. It’s one of those examples that really shows how specialized thermal spray can be.

A lot of the work we do today is focused on helping equipment survive harsh environments, especially around saltwater. If you’ve ever lived somewhere where roads get salted in the winter, you know how quickly salt creates corrosion. Ships and maritime equipment deal with that constantly. Thermal spray coatings help improve corrosion resistance and extend the life of things like steam turbines, pumps, and other critical systems operating near or in the water. We’ve also done work connected to power generation for ships, including steam turbine applications and some work tied to nuclear-related industries.

Energy and Power Generation

Power generation is a really big industry for us right now, especially with everything happening around AI, data centers, and the growing demand for power capacity. It all starts with the power side of things. You’re seeing it everywhere in the news. Companies are building more infrastructure, adding more generation capacity, and trying to support all these advanced technologies that require massive amounts of energy. A lot of the work we do supports the companies making gas and steam turbines, generators, gas engines, and other critical power generation equipment. Nuclear is also becoming a bigger piece of that conversation, and I think we’ll continue to see that grow.

Beyond power generation, we’ve also always had a large presence in chemical manufacturing and general industrial applications. Really, any industry that deals with wear and corrosion — which is pretty much every industry — is somewhere we can help design a manufacturing solution around extending equipment life and improving performance. Similar to metalcasting and forging, thermal spray is one of those niche manufacturing processes that people rely on every day without realizing it. 

Just like METAL works to educate people about the importance of castings and forgings in modern society, there’s also a need for more awareness around thermal spray and the role it plays across industries like aerospace, energy, electronics, and advanced manufacturing. A lot of engineers and buyers may only know the basics, but in the right application, thermal spray can dramatically improve the life and performance of critical equipment.

Jack Watson, business development manager and fourth-generation manufacturer at HFW Industries Inc., learns foundational metalcasting and forging skills from metallurgists at METAL’s hands-on bootcamp at Penn State, Behrend.

Jack Watson, business development manager and fourth-generation manufacturer at HFW Industries Inc., learns foundational metalcasting and forging skills from metallurgists at METAL’s hands-on bootcamp at Penn State, Behrend.

What does being an American manufacturer mean to you?

I explored different things growing up. I always loved construction and working with tangible things. Being around the family business my whole life, I knew I wanted to do something physical and connected to the real world. I’ve often said that even if the family business didn’t exist, I’d still be somewhere in this space because I just really enjoy manufacturing and industrial work. What excites me about metal manufacturing is that it has a direct impact on the world around us. If you like turning your lights on, flying on planes, or even flushing your toilet, manufacturing and metal are part of all of that. I enjoy being part of the infrastructure that helps build and keep the world running.

Then you look at all the different manufacturing processes, metallurgy, material science, castings, coatings, forgings — all these niche technologies that go into the products and infrastructure we use every single day. You can look around any room and see all the different metals and engineered materials that went into creating that space. And that’s every moment of our lives, from the time you wake up until the time you go to sleep. That’s what gets me excited about manufacturing. I love being part of that, and I can’t wait to be a part of several generations of great American industrialists.

Ready to cast your career in metal? Explore METAL’s free online training and hands-on bootcamps to discover careers in metalcasting and forging. Visit our events page to find a bootcamp near you.  

Reach Jack Watson and the HFW Industries Inc. team at hfwindustries.com.  

FAQs

What is thermal spray coating?

Thermal spray is a manufacturing process used to restore or protect industrial equipment by spraying heated materials onto a surface. Manufacturers use thermal spray coatings to reduce wear, prevent corrosion and extend equipment lifespan.

What industries use thermal spray?

Thermal spray is used across aerospace, defense, maritime, energy, semiconductor, and heavy manufacturing industries where equipment must withstand extreme heat, wear, or corrosion.

What is additive manufacturing?

Additive manufacturing refers to processes that build or restore material rather than removing it. While many people associate additive manufacturing with 3D printing, processes like welding and thermal spray have used additive techniques for decades. At HFW Industries, additive manufacturing includes thermal spray coatings and welding, while subtractive manufacturing includes machining, grinding, and polishing. Modern manufacturing relies on a combination of additive, subtractive, casting, and forging processes to create and restore critical industrial equipment.

What is METAL’s bootcamp?

METAL’s bootcamp is a hands-on metallurgy training program designed to introduce participants to metalcasting, forging, and modern manufacturing processes through immersive, college-campus experiences. Led by industry experts, the week-long bootcamps combine technical learning, lab work, foundry tours, and networking opportunities to help strengthen the next generation of America’s manufacturing workforce. 

Why are manufacturers interested in metalcasting and forging?

Manufacturers attend METAL’s bootcamp to better understand foundational manufacturing processes, strengthen industry connections, and prepare for workforce challenges. 

Why is workforce development important in manufacturing?

Many manufacturers face ongoing skilled labor shortages as experienced workers retire and demand for advanced manufacturing continues to grow. Workforce development programs help expose more people to careers in manufacturing and skilled trades.

The Horseman’s Axe: College Students Discover Careers and Community at Cast in Steel 2026

The first time Marisa Holding heard about Cast in Steel, an upperclassman walked into the University of Wisconsin–Madison holding what looked like a spear. Not a prop. Not a replica — a real spear. He pulled an African spearhead from his backpack and explained it was for the Cast in Steel competition. 

“I was lost for words,” Holding said. “What competition has students make weapons on campus that are meant to be functionally tested? I decided then that I was going to join the competition the following year.”  

What is Cast in Steel?

Subscribe to Cast in Steel to see sparks fly on the Season 1 premiere, “George Washington’s Sword,” July 9 at 8:00 p.m. ET on YouTube.

Holding kept that promise, participating in 2025 and 2026 Cast in Steel – a national competition where college students test their engineering expertise by designing and casting metal tools like Thor’s hammer and George Washington’s sword from scratch. This year, 62 teams from universities across the United States came together to cast their own horseman’s axe. But the competition isn’t only about teaching tomorrow’s engineers how to make performance-ready products. For many, Cast in Steel is their first introduction to the craft and community behind modern American manufacturing. 

“The primary goal of this competition is to touch the hearts of young people who’ve never realized that going into manufacturing and making castings or forgings could be thrilling, worthwhile, purposeful and meaningful,” said Raymond Monroe, executive vice president of the Steel Founders’ Society of America, the organization that hosts Cast in Steel. 

Today, more than half of Generation Z, people ages 14 to 29, remain neutral or disinterested in manufacturing careers. In one survey, almost 60% of Gen Z respondents said they might have pursued manufacturing if they had access to related programs in school. 

Programs like Cast in Steel and METAL, both supported through funding by the Department of War’s (DoW) Office of Industrial Base Policy, which manages investments made pursuant to the Industrial Base Fund (10 U.S.C  §4817), are working to change these odds for future generations with hands-on training and real-world metalcasting experiences. 

That mission comes at a critical moment for the industry. By 2033, nearly 4 million manufacturing jobs could be available in the U.S. with only enough workers to fill half the roles. When America’s manufacturing foundation is weak, its defense, energy and other critical infrastructures are left vulnerable to supply chain shortages.

“Our job is to deter a conflict from ever happening,” said Matthew Draper, the technical director for the U.S. Department of War. “To make sure that everyone in the world who is potentially our adversary knows and understands that America is ready to respond, we need people. We need a lot of people in manufacturing.”

This year, student teams from 10 of METAL’s university partners participated in Cast in Steel, including grand prize winner the University of Wisconsin–Madison.  

An Axe to Grind – How to Make a Horseman’s Axe

For six months, 300 college students dedicated their time in between classes mastering the art and science of casting a horseman’s axe. They pulled all-nighters, drove hours to work with industry partners, and some like Teagan Strecker learned how to form and reshape metal for the very first time.  

Strecker, a UW–Madison material sciences major, had no interest in metalcasting. In fact, no one on her Cast in Steel team, The Mad Badger Metalcasters, had attempted casting or forging before. But with mentorship from experienced Cast in Steel competitors, including Holding and Laney Zuelsdorff, Strecker joined in. 

“I didn’t really know what Cast and Steel was, but they promised me it would be fun, so I decided to give it a shot,” she said.

Before firing up the foundries, university teams realized they’d need to win the battle of historical research.  

A horseman’s axe isn’t exactly like an axe used for chopping wood. Rulers like Robert the Bruce, King of Scotland, were believed to use this type of axe in man-to-man combat, wielding the weapon with one hand during combat from horseback. Horseman’s axes were often outfitted with leather wrist straps for utility, langets — or narrow strips of metal — for strength, and spikes for protection. The students’ axes, meant to resemble historical accuracy, could not weigh more than 3.3 lbs or be longer than 31.5 inches.

“The most important thing a lot of teams miss is the research and narrowing down what makes a horseman’s axe, a horseman’s axe,” said Devyn Fidel, a Cal Poly Pomona manufacturing engineering major who competed in Cast in Steel for the second time this year. “It can’t be too front heavy, otherwise it’s really hard to swing.”

Turning ideas into battle-ready weapons was tough — demanding teams of mechanical engineering, materials science and manufacturing engineering technology students, plus the expertise of industry leaders. 

Cast in Steel 2026 Grand Prize Winners, The Mad Badger Metalcasters, from the University of Wisconsin–Madison included Malini Datta-Nemana, Evelyn Dwyer, Chase Edwardson, Mathias Gitterle, Ana Lesmeister, Simon Niemcek and Teagan Strecker. Photo courtesy of UW–Madison’s College of Engineering.

The Messy Middle

In addition to design, students had creative liberty to choose the materials they cast their axes from. Ryson Haag, a mechanical engineering student at Georgia Southern University, said his team’s axe wasn’t pretty, but they were determined to cast a tool that wouldn’t break. They decided to use a modified 8630 steel with extra chromium and experimented with heat treatments to avoid brittleness.

“Our first axe was a sledgehammer,” Haag said, forming a broad triangle with his hands. “With a 40 degree tip, it’s not cutting anything.” 

To overcome design challenges, Haag learned how to use CAD simulation software like SOLIDCast to optimize mold designs and solve metal velocity problems during a pour. Practicing simulations taught him how to make effective molds for investment and sand castings, applying the engineering principles he learned in class to a real-life project.  

“It saved me a lot of time because it taught me here’s what the theoretical says and here’s what better and worse ideas look like,” Haag said. “That is one of the best things I could have gotten out of Cast and Steel.”

Cast in Steel competitors are under a time crunch to complete alloy selection, mold design, casting simulations, heat treatment processes, post-processing finishing, and product testing — often for the first time. The students who participate in METAL’s bootcamps have an advantage. Through METAL’s nationwide training programs, students gain hands-on foundry experience and foundational casting and forging skills before stepping into competitions like Cast in Steel.   

Steven Fedell, a 2026 mechanical engineering graduate from Penn State, Behrend, said his experience with the university’s METAL bootcamp helped prepare him to lead his team to second place in Best Sand Casting.  

“I went into the competition thinking, ‘You have to consider people’s lack of experience and you only have so much time,’” Fedell said. “You could be the smartest person in the world, but if you can’t communicate your ideas to others, does it really matter?”

However, limited experience doesn’t deter students’ motivation or imagination. Daniel Branagan’s team from Michigan Technological University made the unconventional choice to cast a heart-shaped axe head from cast iron steel. The durable, heat-resistant nature of cast iron is perfect for products like skillets and wood-burning stoves, but using it to cast a functional axe was complex.   

“To make cast iron strong enough, you have to go through a specific heat treating process, which is impossible to do on your own,” explained Branagan, a material sciences PhD candidate at Michigan Tech. “You need molten salt baths and carbonizing atmospheres.”

Branagan’s team worked with Aalberts Surface Technologies, a leading surface technology service provider that specializes in metal coating and heat treating for the automotive, mechanical engineering and medical technology industries. Industry partners are an essential resource during the competition, providing students guidance and facilities they may not have access to. Aalberts provided chemistry recommendations and heat treated the team’s axe in addition to funding Michigan Tech’s costs for the project.   

Working with an industry partner showed Branagan how the skills and techniques he used for Cast in Steel are relevant to industrial metal manufacturing. 

“This could very well turn into a job someday,” he said. 

At Miller Castings, engineer Eric Cramer partnered with Cal Poly Pomona’s students. Miller Castings, a lost wax investment casting manufacturer that serves aerospace, military and commercial customers, financially supported the project, provided foundry tours, and mentored the students throughout the investment casting process. 

“I don’t think they realized how much time and effort goes into every step. They learned a lot from the explanations on why their design should be tweaked to get it through the foundry,” explained Cramer, a Cal Poly Pomona alumnus who’s just as invested in the outcome of Cast in Steel as the students he works with. “I really wanted them to win.”

This year, with Cramer’s help, Cal Poly’s License to Steel team won second place for Best Investment Casting. 

“What prepares people the most is being face-to-face with the industry,” said Ethan Beltran De Anda, a mechanical engineering major at Cal Poly. “You actually meet with them and talk to them. Then people in the other groups are your future peers and coworkers. It’s just a really good experience.”

Cast in Steel runner-ups, The Mad-Town Axemen, included University of Wisconsin–Madison seniors Ivan Cermak, Dominic Chione, Marisa Holding, Wen-Yo Yen and Laney Zuelsdorff. Photo courtesy of UW–Madison’s College of Engineering.

Chopping Down the Competition

What matters most after six months of production is having a functional tool to test. For three days in April, every university team meets in Grand Rapids, Michigan for a live, high-energy showdown where industry experts judge the cast creations in a series of performance challenges. 

Dr. Frank Pfefferkorn, a professor of mechanical engineering at UW–Madison, said Cast in Steel is as close to a real-world engineering project as students can get.

“From the very beginning, they have a product they have to deliver,” Pfefferkorn explained. “It’s like you’re a contract manufacturer and you have to make every decision along the way.”

“It builds their confidence that they can do this,” he added. 

Before the event, teams test their weapons at home, slicing into everything from logs and Roombas to playing real-life Fruit Ninja. Then, if the axe survives, it’s ready for the Cast in Steel stage – a moment heightened by TV crews filming the competition. 

“We were really nervous that the ax was going to break,” admitted Breannyn Black, a mechanical engineering major at Michigan Tech. Her team had ideas for optimization, but simply ran out of time. Ready or not, she stepped onto the testing stage and threw their axe into a knight’s suit of chainmail.

“I could not believe it took that first hit. I was so happy,” Black said. “When I hit it again, I was like, ‘Wow, I made something that does its function. It does what it’s supposed to do and it’s impressive.’ I felt pretty empowered by that.”

Performance tests included piercing a two-by-four plank of wood with its spike and cutting into a steel sheet suspended from the ceiling. The teams were not only under the scrutiny of the judges, but their peers from other universities, too. 

“It was cool to see how everyone performed,” said Zachary Platt, a mechanical and manufacturing engineering technology student at the University of Northern Iowa. The spike on his team’s axe wobbled during its performance, knocking them out of the competition. “You can’t win them all, and I’m happy with how ours turned out.”

Not all the axes made it through in one piece.

“I can’t lie,” Fedell laughed, “watching some of the axes shatter spectacularly on stage was pretty neat.”  

Beyond axe performance, students were judged on technical reports, casting creativity, and videos documenting their process. Longtime Cast in Steel judges Patrick Nowak and Forged in Fire’s David Baker say the competition never fails to deliver impressive ingenuity. 

“I like seeing the students’ approaches to the problems they’re given and how they use whatever resources they have to try to meet the contest criteria,” Nowak said.

“The point of the competition isn’t to win or lose,” Baker added. “Don’t get me wrong, everybody’s excited to win, but it’s really about designing and manipulating material to create a tool. It’s an exciting thing to watch and it’s fun to be part of it.”

Cal Poly Pomona team “License to Steel” tests their axe out at home with real-life Fruit Ninja.

The Winning Moment

If there’s one moment Holding, Strecker and Zuelsdorff will never forget, it’s winning Cast in Steel. After three days of brutal product testing, the remaining teams stood on stage, waiting for the final results. One by one the judges named the teams who, unfortunately, did not cast the winning horseman’s axe.    

“Finally, there were two teams left on stage and it was Wisconsin and Wisconsin,” remembered Zuelsdorff. “We had matching shirts, so it looked like one team up there, and we looked at each other and said, ‘We won no matter what. We’re giving it back to our university’s club.’ It was an all-around amazing moment.”

That’s exactly what the grand prize winners, The Mad Badger Metalcasters, chose to do. The team donated the entire $25,000 prize to UW–Madison’s Material Advantage and Foundry Society student chapter. Holding and Zuelsdorff’s team, The Mad-Town Axemen, earned second place — and took pride in mentoring The Mad Badger Metalcasters on an award-winning axe. 

Strecker walked off the stage with more than prize money and bragging rights. She had discovered an entirely new career path. 

“I was not really interested in metallurgy at all before I did Cast in Steel, and now I’m doing it in my job,” said Strecker, who’s an intern at GE Healthcare’s refractory process innovations plant. “Seeing that you can do metallurgy, especially as a woman, inspires you and shows you that metallurgy is still an exciting field to be in.” 

For SFSA Executive Vice President Raymond Monroe, the students’ enthusiasm is all that matters.

“These students are the future of our industry and American manufacturing,” said Monroe. “I’m thrilled we have so many young people who are excited to be involved in our competition, and I look forward to their leadership in the future.”

Ready to cast your future in metal manufacturing? Explore METAL’s free online training and hands-on bootcamps to discover careers in metalcasting and forging. Visit our events page to find a bootcamp near you.  

Watch the Season 1 premiere of Cast in Steel, “George Washington’s Sword,” July 9 at 8 p.m. ET on YouTube.

Creativity is Contagious: Q&A with Yellow Goose Forge’s Jason DiCosimo

Craftsman and retired Marine Corps Sergeant Major Jason DiCosimo started blacksmithing simply because one of his woodworking clients needed custom metalwork. But after he forged metal for the first time, DiCosimo never stopped. 

Today, DiCosimo, 47, is a self-taught blacksmith and bladesmith known for bringing fantasy knives, battle axes and swords to life through forging and metalworking. From Aragorn’s sword, Anduril, from Lord of the Rings to the Call of Duty cleaver and the Catspaw dagger from Game of Thrones, DiCosimo is up for any forging challenge — and he loves sharing the process behind his craft. 

Through his social media channels, Yellow Goose Forge, the artisan blacksmith shows millions of people what’s possible with fire, steel and creativity. But forging isn’t the only craft essential to DiCosimo’s work. Over time, he’s expanded into machining and metalcasting to push his projects even further. After 16 years of teaching himself how to transform raw metal into finished pieces, DiCosimo was thrilled to discover METAL’s metallurgical bootcamp. For nearly a week at Penn State Behrend, DiCosimo learned metalcasting basics, CAD software, foundry processes and the science behind modern manufacturing from professional metallurgists. Here’s what DiCosimo shared about his journey into blacksmithing, forging and metalcasting — and how METAL unlocked new levels in his metalworking world.

Listen to this interview (10min)

 

How did Jason DiCosimo start blacksmithing? 

I first started out woodworking. I was building all kinds of way-out-there things that attracted a lot of strange clientele who had great ideas and a lot of creativity. I had one client who asked if I could find him a set of hinges that were big and ornate with branches and leaves. I looked everywhere for him and I told him I couldn’t do it. I failed him.

He asked, “Should you just make them?” 

I said, “Yeah, probably.” So I started my metalworking journey. From there, it’s just been forging steel ever since.

How did Jason DiCosimo learn forging and metalworking? 

To learn how to forge, there’s really nobody to learn from. There’s a small community of craftspeople out there that do this, but they’re very tight lipped. So you have to look for opportunities to get into forges where they’re doing artist or structural projects. 

Then you go to the bladesmith, who’s only doing blades, and you pick that up. 

Then you’re like, “Oh, I need to weld this piece. Let me learn how to weld. I need to machine this one. Let me learn how to use a mill,” and keep going from there. Playing with metals is a good time.

How did Yellow Goose Forge become known for swords and fantasy weapons? 

I started as an artisan blacksmith. I would do lots of normal blacksmith things — fire pokers, plant hangers, dinner bell triangles, candle holders — that kind of stuff. I was pushed by someone I worked with to put my projects online. So I did, and then Yellow Goose Forge caught traction and started snowballing and snowballing. 

In the comments, people would ask, “Dude, can you make this? Can you make that? Can you make this sword from this video game? Can you make this ax from this movie?” 

From there, it took off. I started getting contacted by movie production companies and TV shows.

What are Jason DiCosimo’s favorite blacksmithing projects?

The ones that I have no idea how to get done. 

My last sword was this big, crazy, out-there fantasy sword. So you’re welding, you’re forging, you’re machining, you’re milling, you’re doing all that stuff on the lathes. Those are the projects I love. The ones you really don’t know how you’re going to do it.

I wish everybody knew the feeling of their first completed project. Whatever it is, no matter how large or small, just the first thing you make with your hands by shaping, machining, or forging metal. When you’re done, you just sit there and look at it, something that didn’t exist before — it existed in a different form. You’re taking something raw and using heat and force to make it into what you want. You can feel it, You can hold it. 

That feeling is something like, “Oh my God, I made this.” It’s super cool.

Why are forging and manufacturing careers a strong fit for veterans? 

Because it takes a certain type of person.

I spent 23 years in the Marine Corps. I retired as a sergeant major in South Carolina, the same place where I went in. It was an amazing, close-the-book moment. But you learn discipline, fortitude and consistency. Those translate into everything.

For service members to transition back into the regular world, it takes a person who’s not afraid to get dirty, but also not afraid to knuckle down and do equations and learn the math and measurements. It takes somebody who can really focus on what’s at hand, especially because of the danger involved. It could be very hazardous if you’re not safe, which is another thing that’s transferable from the military services. Safety is not paramount, safe training is paramount. You’re still doing it, but you’re doing it with intention. 

What do students learn at METAL’s metalcasting bootcamp? 

What I wanted to get out of the bootcamp was sand casting. I’m not good at it, but I can make it look really good. I’ve already gotten so many nuggets of things that’ll fix my work and make it easier with less cleanup at the end.

As far as casting goes, I learned how to properly vent molds, how to lay the molds and gate them, and how to use sprues, risers, and vents appropriately. I wasn’t able to do that before. It was always a calamity. 

The education level of METAL’s instructors is top-notch. The experience is way above what I’m used to in the craft and the trades.

I was also looking forward to going to the foundry. I’ve been in foundries before. I have my own small version of a foundry, but I want to see the large scale — what it looks like and how they do it. Whether you’re doing small or large scale, it’s all the same process, the same tools. Some of the tooling might be smaller or more unique to whatever the process is, but definitely getting to the foundry is what I looked forward to the most. 

How is METAL training the next generation of metal workers? 

When you’re in a trade where not a lot of knowledge gets passed around, coming to a place like METAL’s bootcamp — where people are so willing to give the secrets away and impart their knowledge onto the people coming along behind them — is huge. 

I want to see more competition. I want to see more free flow of collaborative ideas and passing along the skillsets. I want to expose forging to everybody and then let people who naturally want to do it come along like a lighthouse. 

With METAL, all the content, all the information, all the education, all of the skills people need to cast and forge are here. How do you get it out to the masses? You put it in front of as many people as you can, and the ones who are drawn to it will come. 

Why should aspiring metal workers attend METAL’s bootcamp? 

I would say whether you’re looking to get your hands dirty, use new tools, or whether the calculations are your thing, everything from the desk work to the forge work is included in this bootcamp, which is the coolest part. 

There’s something for everybody. I’m not a big fan of math. However, a lot of people love that kind of thing, so calculations it is.

Why is interest in blacksmithing and forging growing?  

What I do in my craft, and how I present it to the world, is I’m making things that people think you can’t make with your hands. They think there’s no way you’re going to be able to make this crazy sword or battle ax. So when I show people the process from beginning to end, when they see the end product, they want to know, “how did you do it?” 

The question I get most often from thousands of people every day is, “how do I learn how to do that? How do I get started?”

The hunger for people to learn forging, metalcasting and hands-on manufacturing is there. We just need to show them how. 

Ready to forge your career in metal manufacturing? Explore METAL’s free online training and hands-on bootcamps to discover careers in metalcasting and forging. Visit our events page to find a bootcamp near you. 

Follow Yellow Goose Forge on YouTube, Instagram, TikTok and Facebook. 

FAQs

What is blacksmithing?

Blacksmithing is the process of shaping and forging metal using heat, tools and force. Blacksmiths create everything from decorative ironwork and tools to knives, swords and industrial metal components.

What’s the difference between forging and metalcasting?

Forging shapes heated metal using force from hammers, presses or dies, while metalcasting involves pouring molten metal into a mold to create a finished shape. Both are essential manufacturing processes used across industries including defense, aerospace, automotive and energy.

How do beginners learn blacksmithing and forging?

Many beginners start by watching online tutorials, attending workshops, or enrolling in hands-on manufacturing training programs and bootcamps. Learning forging often includes skills like welding, machining, metallurgy and shop safety.

What careers are available in forging and metalcasting?

The metal industry offers careers including blacksmithing, forging, welding, machining, foundry work, CNC operation, metallurgy and tool-and-die manufacturing. Skilled workers are needed across defense manufacturing, transportation, aerospace and industrial manufacturing.

Why are manufacturing careers a good fit for veterans?

Manufacturing and forging careers often align well with military experience because they require discipline, attention to detail, safety awareness and problem-solving skills. Many veterans transition successfully into skilled trades and advanced manufacturing roles.

What is sand casting?

Sand casting is a metalcasting process that uses compacted sand molds to shape molten metal into finished parts or components. It’s one of the oldest and most widely used casting methods in manufacturing.

Can blacksmithing become a career?

Yes. Modern blacksmiths and bladesmiths build careers creating custom metalwork, artistic pieces, knives, swords, architectural ironwork and industrial products. Many also teach classes, create online content or operate fabrication businesses.

What industries rely on forging and metalcasting?

Forging and metalcasting are critical to industries including aerospace, automotive, defense, shipbuilding, construction, medical manufacturing and energy production.

How can someone get started in manufacturing training?

People interested in forging, metalcasting and manufacturing careers can begin through free online training programs, community college courses, apprenticeships, trade schools and hands-on bootcamps like METAL’s workforce training programs.

Uniting Small Manufacturers: Q&A With Russell Winter, Founder of US MFG

Russell Winter has spent most of his life on a machine shop floor.

As a third-generation tool and die maker, Winter cut his teeth at his grandfather’s company in Illinois, where he learned how to finish die castings and machine precision parts. What began as a small tool and die operation in the 1970s has evolved into Center Tool Co., the milling, turning and machining company Winter leads today.

But Winter wasn’t handed ownership of his family’s business — he had to earn it. Under the guidance of his father, Allan, the second CEO, Winter spent years mastering mills, CNC machines, CAD design software, welding and part repair. Like many manufacturers, he learned a few lessons the hard way, spending late nights on the shop floor making up for early-days mistakes.

Now 32, Winter is president of Center Tool Co., a champion for small businesses and founder of US MFG, a network that helps small metal manufacturers grow, scale operations and pass ownership to America’s next generation of industrial entrepreneurs.

At a recent METAL bootcamp, Winter spoke to us about his founder journey, the future of the metal industry — from CNC machining and precision tooling to metalcasting and forging careers — and how US MFG is reinforcing the manufacturing community for long-term success.

Listen to this interview (15min)

 

Why did you launch US MFG and how is US MFG helping small metal manufacturers grow?

Russell Winter: My story started with Center Tool, but then it led to US MFG, which is now what I spend most of my time on. After I bought the business from my dad in 2019, I started having more conversations with other owners of small businesses. I realized all these guys are retiring, they’re aging out of the workforce.

My dad’s generation was told, “You got to take over the family business. You’re the only one that’s going to do it.”

My generation was told, “Go to school, join the military, do what you have a passion for.” Those of us that grew up in family businesses saw how much stress it was running and managing it. So for good reasons, I think a lot of this generation hasn’t taken over family businesses. I was realizing that could be a problem.

What happens to all these companies that are owned by Baby Boomers looking to retire and no one is going to take them over? That got my wheels turning back in 2019 when I was having those conversations and that eventually led me to starting US MFG.

We built software that allows small businesses to connect with each other and streamline their operations and workloads between companies. What we realized was being a small business, you can easily get backlogged or easily be dead and have no work — there’s a lot of fluctuation. When we have two companies that work together, they can help balance their workloads.

Right now we’re focused on getting small manufacturers cybersecure so they can get into defense work. Then the platform is built to start getting them into the defense industrial base, get them more work and make them healthy. Succession I think will follow a healthy company.

What challenges did you face while building US MFG?

Russell Winter: I started it with the mission mindset of saving small shops and good jobs in small communities because that’s where I grew up. We wear steel toe boots and flannels and we like to go fishing and we’re not looking to be billionaires, but we want a fair salary or hourly rate and flexibility. So I started it with that intention and I thought if we built this software, we could raise money and buy all these small shops. It took me a few years. I was homeschooled, grew up on a farm, and grew up in the shop. There were a lot of things that I had to learn the hard way.

One of those things was, is it even worth buying small shops? Are they a good investment? It was a painful realization for me because I felt more of the mission drawn to buying these companies than the financial outcome. And I realized that a lot of them are not investible.

If they’re old and have depreciated equipment and old buildings and they’re making an 8% margin at the end of the year, it’s not an attractive investment. So how do you raise money to go buy those and say you’re going to pay back investors and buy new machines?

Then I had to refocus and tackle it by saying, “Well, let’s get these shops more work, and then they’ll grow and be healthy.” That’s how you can help sustain them. 

I think there is a need for aggregating the capacity that small manufacturers have. A lot of us are operating one shift a week, 40 hours, probably utilizing half of the machines we have on the floor. So there’s a lot of unused capacity in these businesses. If you could get them to work together, even just on a platform level, you could utilize them more for bigger contracts.

We’re at the point where we have this software, we got into defense work on our own as a three person shop and got all our certifications. We know that we can help other people do it, but we’re at the stage where we need to raise money or get enough capital so we can hire a team to fully build US MFG out and expand it.

What challenges are small metal manufacturers in the U.S. facing today?

Russell Winter: I think one of them is that small manufacturers are really good at making parts. That’s what they want to spend their time on, not fighting to get work. 

On the defense side, with cybersecurity certifications and requirements, when we did it, I basically spent my full time figuring out the compliance side, and my other buddy built the software, and my other one was doing the machining. It’s a lot to expect a small manufacturer to either be able to afford to hire someone for $100,000 to get compliant or to dedicate all their time to that when they’re already trying to fight for work. I think if they had more work and a better idea of what type of work best suited their facility, they would do great at making parts.

Another challenge is, culturally, a lot of people talk about how it’s hard to hire, and I’m probably not the best person to speak for it because we have four people. I’ve probably hired four people in my life. It’s never been an issue for me to find those people, but I’ve only hired four. So I think a big part of the hiring issue, though, has to do with culture and how do you attract new employees? It’s your company culture. That’s one of the top three selling points for how to attract people nowadays, and a lot of shops need to update their culture. They need to be a little bit more relevant and flexible, and there are plenty that are doing it, and they’re hiring people.

I would say let’s get more work, get your culture healthy, and then you’ll have the people to do it.

How can metal manufacturers attract more work and talent?

Russell Winter: On the culture side of things, I think something that would be very helpful for young people coming in is having a career roadmap. Our local high school has a shop program. By the time they get out, they could already have three or four years of hands-on programming and machining. By the time they get to employment, we probably already worked with them for a year or two. We did that with one apprentice. We brought them on while they were still in high school. But give them a roadmap — don’t just say, “Hey, you’re going to do this for the next 20 years you’re here.” Because they probably won’t be there for 20 years. But if you say, “This is what we need you for now, if you learn these skills, this is the kind of raise you’ll get,” and build something out that shows them the future of achieving what they want out of life.

And be open to new ideas. Even if you think it’s a bad idea, be open to it as long as it’s not going to be a catastrophic failure. Allowing someone to fail is really good for retention and growth, and isn’t that what you want? 

I know that because that is how my dad ran the shop when I was growing up. I made a pretty big mistake one time and we had to scrap 10 grand worth of parts. I sent a part after heat treating, we machined it, hard machined it, sent it out. Normally, we send it out for nitriding because they were mold tooling inserts, and I sent it out for heat treating again. So when it came back, it was warped and we couldn’t fix them. All I did was sign the wrong stuff on the order sheet for the treatment.

When I realized that, it hit me like a ton of bricks.

I was like, “Oh, Dad, I just screwed up.”

He said, “All right, you just got to go remake them.”

I almost wanted him to blow up at me because I felt so bad about it. Nope, I just slept at the shop in front of the machine and made the parts. I got it done, but that taught me responsibility.

What made you want to join METAL’s metal manufacturing bootcamp?

Russell Winter: I first heard about METAL’s bootcamp at Reindustrialize last year. I think this is such a huge opportunity when you have free training open to everybody, and getting into a career that gives you a lifestyle you want. I just had to see it for myself.

The METAL bootcamp being about casting and forging is outside of what I normally work on with machining and fabrication. That was a lot to learn, but I was like, “I wish I knew this already,” because it applies. There’s a lot of crossover. Even on the machining side, I learned about diamond turning. There’s always something to learn.

How do programs like METAL help manufacturers overcome workforce challenges?

Russell Winter: I definitely think more education and more awareness of the opportunities in manufacturing solves challenges because a big part of it is that people genuinely don’t understand it and don’t know about it. So bringing awareness to manufacturing and working with schools and getting kids that aren’t currently in the school system into the program, I think that works to solve it.

Mostly I’m looking at METAL as a huge resource to direct people when they’re not sure what they want to do. It’s just like, “What are you going to risk?” It’s a week. Learn about it and experience it, whether you’re from that background or not. You’ve got nothing to lose to learn about this opportunity. I think people will find it more interesting than you think. It’s pretty fascinating.

Why is rebuilding metal manufacturing critical to national security?

Russell Winter: There’s a certain level of industrial base that you need to maintain so that you can produce things that you need. You don’t need to make everything, right? I think there’s reasons to buy from other countries and to have allies. But on the national security side, if you’re playing on the global stage and you have other powers that are not aligned with your interests, you need to hold your own. If you don’t have an industrial base that can support holding your own, you lose. On the defense side, that’s very important. On the other side of national security, we saw with COVID we didn’t make a lot of the personal protective equipment. Well, when you need it, when the world needs it, whoever makes it keeps it.

There’s a lot of different ways that applies, but it’s a foundational sector of the economy and it’s been dying here for generations. Because I used to be focused on buying the small shops, people have reached out like, “Hey, I want to buy a small company. I want to buy a manufacturer.” That’s great there’s a lot of interest in it, but it helps to understand manufacturing before you want to own a company. They should come to METAL.

What excites you most about the future of the metal industry?

Russell Winter: It’s weird growing up and it never really being talked about. It was kind of like a hidden career. People didn’t talk about it like they were proud of it. But I see on Instagram and X people who have this lifestyle where they afford their house, they bought a car, they have a family. It’s like, “Oh wow, they’re 30 years old and they did this. What did you do? ‘I’m a welder. I’m a pipe fitter. I’m a machinist.’”

It really excites me that there’s more awareness of the need because that’s a lot of opportunity. I have little brothers, and their Gen Z uncertainty in careers is a big deal right now. I think these careers will be around for a long time. This is a healthy pathway to take for a while. 

So mostly the opportunity that’s out there, and seeing that policies and government are getting behind manufacturing now — that’s what’s needed. That’s one of the main reasons why it diminished. As a country, we’re moving to support it and METAL is a direct result of that. This is the government saying, “We’re serious about this. We will pay for people to come and get trained just to show them the opportunity that’s here.” I see it as a pivotal moment in policy where it’s like things are changing, so that’s exciting to me.

Ready to build your future in metal? Start METAL’s free online training, explore hands-on bootcamps and discover careers in metalcasting and forging. Visit our events page to find a bootcamp near you.

Connect with Russell Winter on LinkedIn, X, or reach out to him at usmfg.com.

FAQs

What does a tool and die maker do?

A tool and die maker builds and repairs the tools used to manufacture metal parts, including molds, dies and fixtures. Tool and die makers often use precision machining, CNC machining, CAD software and welding to create highly accurate parts.

What is CNC machining in the metal industry?

CNC machining is a manufacturing process that uses computer-controlled machines to cut and shape metal. It is commonly used by metal manufacturers to make precise parts for industries like defense, automotive and aerospace.

Why are small manufacturers important to the metal industry?

Small manufacturers play a major role in the U.S. metal industry because they produce specialized parts, support local jobs and strengthen the domestic supply chain.

Are there good careers in the metal industry?

Yes. Careers in the metal industry include tool and die maker, machinist, welder, CNC operator, manufacturing engineer, and skilled roles in metalcasting and forging such as foundry technician, patternmaker, melt operator, forge press operator and metallurgist. Many of these metal manufacturing careers offer strong pay, hands-on work, long-term stability and opportunities for advancement across industries like defense, automotive and aerospace.

What is the difference between metalcasting and forging?

Metalcasting creates parts by pouring molten metal into a mold, while forging shapes solid metal using compressive force. Both are essential processes in modern manufacturing and offer strong career opportunities across defense, automotive and aerospace industries.

***

The Skills Gap Threatening America’s Foundries: How Keystone Development Partnership Plans to Fix It

Keystone Development Partnership (KDP) launched 20 years ago after a massive skills gap derailed Pennsylvania’s transportation industry. Now, America’s metal industry faces a similar situation. An unprecedented labor gap has emerged, and KDP, Jobs for the Future (JFF) and METAL are working fast to repair it. 

For the first time since WWII, America needs more metal workers. 

By 2033, there could be nearly 4 million manufacturing jobs available across the country. But without stronger training pipelines, almost half those jobs could go unfilled, threatening national defense and U.S. supply chains. 

An aging workforce and reindustrialization have lit a fire under metal manufacturers — and the nation. 

“American prosperity and security depend on the development and promotion of competence,” President Donald Trump wrote in the 2025 National Security Strategy. “Cultivating American industrial strength must become the highest priority of national economic policy.”

But the most experienced metal workers are tired of keeping the irons hot. 

Millions of Baby Boomers are retiring, or trying to. Debra Killmeyer, a KDP project consultant and former dean of workforce at the Community College of Allegheny County, says labor shortages keep metal manufacturers and their employees under strain. 

“I talk to companies with people who’ve been there 44 and 46 years about how they can’t retire because they don’t have their replacement,” Killmeyer said. 

Since 2000, workers 55 and older have been the fastest-growing age group in the workforce, according to the United States Census Bureau. In manufacturing, the shift has been more pronounced. In 2022, 40% of employers had workforces made up of at least one-quarter older workers, nearly triple the rate of two decades earlier. States with older populations, including Maine, Pennsylvania, New York and Illinois, rely more on workers who are 55 and older.

Source: https://www.census.gov/library/stories/2025/12/older-workers.html 

“That is where apprenticeships help,” Killmeyer said.

In partnership with METAL, a program led by IACMI – The Composites Institute®, with funding from the Department of War’s IBAS Program, and Jobs for the Future, KDP is forging Pennsylvania’s next generation of metal workers through registered apprenticeships. 

History Repeats Itself

This is not the first time KDP Executive Director John Tkach has watched an essential industry fall behind.

In the 1990s, Tkach worked for the Public Transit Agency in Pittsburgh as Pennsylvania’s buses underwent a technological transformation. The old General Motors “fishbowl” buses were being replaced with higher-tech Neoplan models. Before long, more than 1,000 Neoplan buses were on the roads.

“One day, buses became computers on wheels,” Tkach said. For years, the buses stayed under warranty and went back to the manufacturer for repairs. When the warranties expired, transit mechanics were suddenly responsible for maintaining machines they had never been trained to understand. 

“When they went out of warranty, these vehicles had between 500,000 and a million miles on them,” Tkach explained. “Then it was the transit worker who had to take care of it, and they didn’t have the experience or knowledge.”

Today’s metal industry faces the same challenge.

Automation is creating safer, more accessible foundries — and deepening the industry’s skills gap. More training is required to operate the robotic arms, automated pouring systems, and autonomous cranes that now do the heavy lifting. 

“It’ll always be a process with people,” said Dr. Robert Voigt, a professor of industrial and manufacturing engineering at Penn State University. “But the demands on the workforce have gone up in terms of the application of knowledge at all levels.”

In 2000, Tkach conducted a skills gap analysis for the Public Transit Agency, learning what skills the mechanics and technicians needed to repair modern buses and developed a training curriculum. Soon, Pennsylvania’s Department of Labor and Industry wanted in-depth labor research conducted for other industries. Five years later, the Pennsylvania AFL-CIO, a statewide federation of labor unions, launched the Keystone Development Partnership. 

“My passion is to ensure businesses have the skilled workers they need and workers have the opportunities,” Tkach said.

Today, KDP is the driving force behind Pennsylvania’s manufacturing ecosystem, connecting employers and workers to the training resources they need to thrive. 

Forging the Future Together

KDP has partnered with Jobs for the Future, a nonprofit transforming education and workforce systems, to strengthen manufacturing apprenticeships for nearly a decade. They’ve expanded industrial manufacturing technician programs across the state, supporting almost 900 workers in everything from metal fabrication to food processing to bio-medical production. In total, KDP has managed program administration for 3,600 apprentices. 

Brian Paterniti, the director of workforce development of The Manufacturers’ Association, said one benefit to working with KDP is its extensive community network, including union and non-union companies, local workforce development boards, job centers, training providers, and community organizations. 

KDP also offers the Registered Apprenticeship Navigator program, a registered apprenticeship program that prepares people to assist employers and other organizations in developing and registering apprenticeships across Pennsylvania. So far, KDP has trained 150 people through the program.

“Apprenticeships are not easy. It’s difficult. It’s a lot for the apprentices and the employer,” Paterniti said. “KDP, JFF and METAL make it easy. John and Deb are right there, holding the manufacturers’ hands.

METAL’s partnership with JFF and KDP is helping manufacturers do more than fill open jobs. It’s offsetting training costs and revitalizing a metal workforce that’s built to last. Training an apprentice without experience can cost nearly $9,000, according to one Department of Labor study. That doesn’t include the price of an apprentice’s travel, salary and equipment. 

Through METAL and JFF, casting, forging and plate rolling companies across the country can receive assistance in developing an apprenticeship or other work-based learning programs. This funding is also eligible for training equipment and instructor costs, curriculum development, program design and implementation, and support services for apprentices. 

“We’re seeing a growing gap in the workforce. Experienced, highly skilled workers are retiring, and too few younger workers have the training needed to step into those roles,” Tkach explained. “Employers are looking for quick fixes, but the real solution is a long‑term strategy. That’s what registered apprenticeships provide — a reliable pipeline to develop your own skilled workers.”

More than 65% of manufacturers say attracting and retaining talent is their top business challenge. Apprenticeships are solving this problem — and introducing younger generations to career options that don’t require college. According to the Department of Labor, 94% of people who complete a registered apprenticeship stay employed with average salaries of $84,000 a year. 

“Apprenticeships reduce the risk for the employer with a tried and true system,” Killmeyer said. “With METAL’s funds, I’m able to sit down with casting and forging companies and take the time to listen to each of their challenges and help them find solutions.” 

More than anything, foundries need people who are ready to be hands-on in casting America’s future.

Your Apprenticeship Starts Here

Tkach and Killmeyer have spent decades navigating workforce challenges for one reason: apprenticeships create careers — and change lives. 

KDP’s network reaches veterans, immigrants and refugees, women in trades, formerly incarcerated individuals, and people in addiction recovery through community partners and apprenticeship sponsors. With decades of experience, Tkach’s team is connecting underrepresented communities to meaningful work in metalcasting and forging.

“It’s been really nice helping populations that may not otherwise know or have been exposed to these types of careers,” Killmeyer said. “Being able to do that makes a difference.”

Tkach will never forget one apprentice he met through Pennsylvania’s Office of Vocational Rehabilitation, which helps people with disabilities enter the workforce. The apprentice, a young man, was eager to pursue a career in metal manufacturing, but needed additional support in the classroom.

“He said, ‘I’m not stupid. I learn differently. This apprenticeship program was exactly what I needed,’” Tkach remembered. 

The apprentice told Tkach he never imagined he would have a career — or a house and a family of his own. Today, he has all three. His employer is even considering him for a supervisor role.

“All because of an apprenticeship,” Tkach said. “That’s what it’s all about.”

Ready to forge a stronger workforce? Learn how JFF can help your company implement an apprenticeship or other work-based learning programs here.

Cast your career in metal. Register for our free online training, then visit our events page to attend the next METAL bootcamp near you.