Cast Your Future Casts Wide Net of Resources

The metalcasting industry is a vital piece of modern manufacturing, producing essential components that keep the world running. Despite its critical importance, the industry faces a challenge in connecting with the next generation of skilled workers.

Highh school students often overlook the dynamic, well-paying careers available in foundrie, simply because they are unawarethat these opportunities exist. To address this, METAL partner Non Ferrous Founders Society (NFFS) has launched a new website called Cast Your Future.

METAL, led by IACMI – The Composites Institute®, and funded by the Department of War’s Office of Industrial Base Policy, was built to revitalize American manufacturing through hands-on training in casting and forging. 

The concept for Cast Your Future originated from a pressing need to unify workforce development efforts across the country. Supported by a grant from the ATI Foundation, the project was developed to create a centralized platform that actively promotes metalcasting careers.

Bill Padnos, Director of Workforce Development at NFFS played a key role in bringing Cast Your Future to life. “This industry doesn’t have a single place to go that promotes metalcasting careers and resources, and that helps industry utilize what’s available out there,” he said.

Padnos points out that stakeholders frequently suffer from a paralyzing lack of direction, stating, “I always say there’s an analysis paralysis because there are so many programs and activities out there that people don’t know where to start.” He emphasized a need to celebrate the work itself, noting that “there was no site out there that talks about the craftsmanship and the dynamic nature of the industry, and we wanted something that was going to capture that.”

Bootcamp participants pour molten aluminum into molds.

METAL Bootcamp participants pour molten metal as part of the hands-on training.

Because metalcasting is rarely taught in high schools, or even at the community college level, students need accessible entry points to experience the trade firsthand. Through K-12 workshops and university bootcamps, METAL introduces students and career seekers to modern metalcasting and forging careers. Participants can complete METAL’s free online training before attending immersive, in-person bootcamps led by professional metallurgists and manufacturing experts across the country.

Padnos explained how Cast You Future and METAL perfectly complement each other, “what METAL provides is an on-ramp for people who are potentially interested in careers. We wanted to use this site to spark their interest, but then also, after you’ve done a bootcamp or online the curriculum, there’s a place you can go to find out more information.”

One of the most significant challenges in workforce development is maintaining momentum after a student’s initial introduction to the field. Short-term programs often succeed in exciting students about industrial careers, but engagement frequently drops off immediately afterward. “We concentrate on the smiling faces when they come in and when they leave, but what happens the next day? Same thing with schools: you give a kid a diploma, maybe they tell you where they’re going, but then that’s it… You need that next day. That’s where manufacturers drop the ball,” stated Padnos.

Without a follow-up strategy, the industry loses potential talent simply because no one tells students what to do next. Cast Your Future provides METAL participants and others with resources after they achieve their certification. METAL’s K-12 programming and follow-up levels provide a long-running series of touchpoints that can help sustain that initial excitement.

To ensure the platform serves the entire metalcasting ecosystem, Cast Your Future segments its resources, offering specific, tailored pathways and toolkits for students, educators, and industry alike. METAL training and the long-term career navigation available through this new digital hub means the metalcasting industry is no longer waiting for talent to walk through the door; it is actively forging the path to bring them there.

Bradley White with Penn State University METAL Program

Check out this episode of Industrial Talk featuring Bradley White with Penn State University METAL Program.

Industrial Talk is onsite at Penn State and talking to Bradley White with Penn State University METAL Program about “The Profession of Metallurgy”.

The Industrial Talk podcast episode, sponsored by the Propane Education and Research Council, features a discussion with Bradley White from Penn State’s METAL program. The program, which stands for Metallurgy, Metallurgical Engineering, Trade, Apprenticeship, and Learning, aims to train the next generation of workers in foundry skills. White, with 32 years of industry experience, is helping to establish a foundry lab at Penn State Barron, expected to be operational by 2027-2028. The program, funded by the Department of Defense, is expanding nationwide, with schools like Ohio State, Tennessee, and Purdue joining. The initiative emphasizes hands-on learning and real-world skills to inspire future industrial leaders.

Manufacturing Dive: Reality show Cast in Steel aims to attract next generation of metal casters

Original source: Manfacturing Dive

Six teams from schools across the U.S. cast and forge one of George Washington’s swords in a competition to win $25,000. The series is funded through a Defense Department $16.3 million contract.

A Department of Defense’s multimillion-dollar contract has brought a metal casting competition to the worldwide stage as reality show competition in an effort to spread awareness of the skill trade and inspire a new workforce.

Six teams from schools across the United States will be competing for a $25,000 cash prize on the season one finale of the metal casting reality show, Cast in Steel, airing Thursday on YouTube.

Read the story

Modern Casting: Reviving the Metalcasting Workforce: Keystone Foundry Trains the Next Generation

Original source: Modern Casting, August 2026 Issue

Twenty years ago, Adam Scheloske set out to transform Keystone Foundry into a world-class metal manufacturer. Today, METAL is helping fuel that vision — training the foundry’s workforce while preparing the next generation of American metal workers.

Read the story on page 28

Gear Technology: METAL’s Manufacturing Workforce Network

Original source: Gear Technology

A DoW-funded partnership brings online courses and hands-on bootcamps to Purdue’s foundry lab, training that feeds gear production.

Many students and job seekers are unfamiliar with the advanced technologies and career opportunities available in metal casting and forging. But thanks to the Metallurgical Engineering Trades Apprenticeship and Learning (METAL) program, led by the IACMI-The Composites Institute, that is changing. METAL is partnering with universities to showcase the rewarding careers these industries offer. Together, these institutions are hoping to revitalize American manufacturing by delivering responsive, scalable, and sustainable workforce development programs.

Read the story here

Closing the Manufacturing Skills Gap with IACMI’s Mike Kubacki and Elliot Keas (Part 1)

Check out this episode of Manufacturing Unscripted featuring Mike Kubacki and Elliot Keas with IACMI, The Composites Institute.

Peter Parsons sits down with Mike Kubacki and Elliot Keas of IACMI, the Institute for Advanced Composites Manufacturing and Innovation, to talk about how they’re building the next generation of the manufacturing workforce. Mike directs the METAL program and Elliot directs the ACE program, and together they break down how these initiatives connect academia, industry, and government to close the skills gap in advanced manufacturing.

They dig into the K through 12 outreach efforts getting kids hands-on with sand casting and machining before they ever set foot in a factory, why foundries have declined 40 percent over the past 20 years and what that means for national defense, and the career paths (apprenticeships, boot camps, internships) that can lead to a six figure salary without a four year degree.

Mike and Elliot also share their own winding paths into manufacturing, from wire bonding microelectronics for space and defense projects to leading 600,000 square feet of manufacturing operations. This is part one of a two part conversation. Join us next episode as we continue the discussion with Mike and Elliot.

A Future in the Foundry: Wisconsin Precision Casting Corp. Teaches Anyone Who’s Ready to Cast

When Shannon Partick was 18, he applied for a job in the metal industry and was turned down.

Patrick grew up working with tools. He knew he could quickly learn the skills needed for the machine shop role he wanted, but the hiring manager told him he needed industry experience.

“He said, ‘Go out and get some experience and come back,’” Patrick remembered. “I asked him, ‘How am I supposed to get experience if nobody will hire me?’”

The manager didn’t have an answer.

“At that point, I said to myself, if I ever got into that position, I was never going to be that guy,” Patrick said. He’s been true to that promise.

Patrick worked his way up from the foundry floor to become plant manager and co-owner of Wisconsin Precision Casting Corporation, a precision investment casting manufacturer. Today, he does whatever he can to help metal workers get their start, including K-12 outreach and mentoring college students in the Cast in Steel competition.

Wisconsin Precision Casting Corporation produces investment castings in more than 180 alloys for industries ranging from agriculture and construction to medical equipment and food processing.

Lighting the Way to Metalcasting and Forging

When Patrick began his manufacturing career in the 1980s, U.S. steel employment had fallen 57% as foreign competition contributed to layoffs and plant closures. Jobs were scarce, and newcomers often struggled to find opportunities to learn skilled trades.

Now, manufacturers face a different challenge. By 2033, there could be almost 4 million manufacturing jobs available in the U.S., without enough workers to fill nearly half the positions. As the nation rebuilds its metal workforce, employers like Wisconsin Precision Casting are looking for applicants who are reliable and eager to join the foundry’s mission.

“If someone is willing to learn, if they’re open-minded about things, I can teach anybody how to be successful in this environment,” Patrick said.

METAL, led by IACMI – The Composites Institute®, and Cast in Steel provide students and entry-level workers more opportunities to gain hands-on metal manufacturing experience — before applying for a foundry job.

From immersive K–12 workshops to metallurgy bootcamps and paid apprenticeships, METAL introduces learners of all ages and backgrounds to metalcasting and forging. Cast in Steel challenges college engineering students to push their problem-solving skills by designing and casting a fully functional metal tool or weapon. Teams from across the country then come together to test their castings in a three-day competition.

Both METAL and Cast in Steel are 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), to accelerate the development of a highly skilled, self-sustaining U.S. workforce.

Watch new episodes of Cast in Steel on YouTube.

Learning Beyond the Classroom

Zachary Plett, a mechanical and manufacturing engineering technology student at the University of Northern Iowa, realized he was in over his head when he signed up to compete in the 2026 Cast in Steel Horseman’s Axe Challenge.

Plett, 20, had learned sandcasting in his university’s foundry, but his team needed professional guidance to produce an axe strong enough for the competition’s performance tests. The students drove almost four hours to Wisconsin Precision Casting, hoping the foundry team could help bring their axe design to life.

Plett remarked it “blew my mind” when he saw the scale of the operation.

“The same guys are back and forth all day pouring, putting in different molds,” Plett said. “It was a really good experience because it opened my eyes to how big it all truly is.”

Michael Malek found a different path into the foundry. The 25-year-old product engineer accepted a job with Wisconsin Precision Casting right out of college. He knew he wanted a career in manufacturing but wasn’t sure how he could use his mechanical engineering degree to solve real industry problems.

“I didn’t know I was going to find my way to investment casting. That wasn’t necessarily covered,” Malek said about his college courses.

In Patrick’s experience, most engineers who apply to the foundry immediately after graduation are “very, very green” in investment casting.

“Very few universities offer investment casting, and when they do, everybody I’ve talked to said it’s maybe one chapter,” Patrick stated.

At Wisconsin Precision Casting, Malek began developing hands-on skills that built on his college education. Only two years into his role, Malek works directly with customers on part designs, optimizes mold production and maintains the foundry’s robot. The robot is central to the shell-building stage of investment casting. It coats injected wax parts in ceramic, creating shells that are later filled with molten metal to produce the final castings.

“Until you get into the field, you don’t know what skills you will need to sharpen,” Malek said. “Coming here has been really fun and interesting because you learn something new every single day. You’ll never be bored.”

METAL’s metallurgy bootcamps help bridge the gap between classrooms and metalcasting. For up to a week, students and career seekers get an in-depth look at industry design and simulation software, material compositions and pouring processes.

Anyone interested in learning metalcasting, forging or advanced manufacturing topics can start the experience with METAL’s free online training. After completing the required online training and earning a Credly badge, participants travel to one of METAL’s partner universities. There, leading metallurgists mentor them through their first casting pour.

“You walk into the foundry and watch metal being poured. You’re taking something that’s a liquid at 3,000 degrees, and you’re going to turn it into a solid shape,” Patrick said. “It’s cool.”

Whether it comes through a METAL course, Cast in Steel or an internship, Patrick believes any time spent in a professional foundry is invaluable. By working with the Wisconsin Precision Casting team, students learn about investment casting, foundry automation and the expectations they will face in the workplace.

“They learn about what your boss will ask you, which can be a tough lesson,” Patrick noted. “Sometimes you get that in the moment at work instead of as an intern or a college student.”

Wisconsin Precision Casting’s robot builds ceramic shells around wax patterns, preparing them to be filled with molten metal. Product engineer Michael Malek helps maintain and program the system, which he says has made the process safer and expanded the range of castings the foundry can produce.

What Do American Foundries Need Most?

Exposure.

Jose Duran, a supervisor at Wisconsin Precision Casting, has been with the company for more than 20 years. But until he applied for a job there, he didn’t know what a foundry was.

Interested in mechanics, Duran attended a technical school after high school and realized he didn’t want to turn his love for cars into a career. He decided to return home to Wisconsin to figure out his next move.

“I just had to get a job, and then I got this opportunity to see what a foundry was,” Duran said. “I never knew what a foundry was until I started working here. It was different from everything else.”

Duran accepted an entry-level role setting castings. He discovered life in the foundry wasn’t easy — it was interesting, exciting and hot — but he was up for every challenge it offered. Duran soon moved into a melter role, where he received extensive training in alloy chemistry from his teammates and supervisors. Like generations of foundry workers before him, Duran developed his skills on the job as experienced employees passed down their knowledge.

“It’s an industry where it’s fun. You learn from it. You get better at it. You don’t have to have a master’s or Ph.D. or anything. We’ll show you,” Duran said. “That’s how I came up. I worked through all these years and I got to the position where I’m at because I understood the job.”

More than two decades later, Duran has turned a skilled trade he didn’t know existed into a career with purpose.

Patrick believes more people might choose this career path if they learned about metalcasting sooner.

“To be honest with you, it should go back to junior high — the middle school levels of metal shops and the industrial arts, exposing kids to power tools and saws and drills,” Patrick said. “Show them you can make things and you can fix things.”

“When they started taking industrial arts out of the middle schools and even out of high schools, I think they did a disservice to this country,” he added.

Patrick does what he can to create those early experiences. He donates materials to local high schools, including 500 pounds of aluminum for one school’s sandcasting program, and provides foundry tours to interested student groups. He encourages teachers to reach out to see how they can introduce more young people to the possibilities of metal manufacturing.

“If I see excitement, I’m going to give you all the time that you desire,” Patrick said.

METAL also offers mini foundry experiences for K–12 students. Typically organized through partnerships between METAL’s university hubs and local schools, the workshops introduce students to metalcasting careers through fun, hands-on projects they can take home.

For metal workers, Wisconsin Precision Casting continues investing in employees after they’ve been hired through tuition reimbursement and a paid tool-and-die apprenticeship.

“I don’t know how we could make it any more attractive,” Patrick said.

He added, “we get to see all the different things we make that have an impact on somebody else’s life.”

Patrick never forgot how difficult it was to get his start in metal. Now, whether he’s welcoming a student tour, mentoring a Cast in Steel team or hiring someone new, he’s dedicated to giving the next generation their chance.

Ready to begin your metalcasting career? Start with METAL’s free online training, then visit our events page to find a hands-on bootcamp near you.

METAL on Base: Event Brings Hands-on Training to Service Members

Directives from Secretary of War Pete Hegseth and the Secretary of the Army have emphasized the importance of expanding the defense industrial base and integrating advanced manufacturing. Failing to produce necessary components at home poses a severe risk to national defense. The Joint Advanced Manufacturing Symposium (JAMS) was held at Fort Campbell, Kentucky in early August to address these concerns. The event brought together military and civilian leaders, experts, and industry partners to address critical needs around advanced manufacturing and defense.

IACMI CTO Dr. Uday Vaidya provided an overview of IACMI’s work with composites in the defense sphere.

JAMS aimed to bridge the gap between component developers and the warfighters who use them. The symposium covered topics including accelerating innovation, enabling on-demand part production, improving operational readiness, and decreasing reliance on vulnerable, traditional supply chains.

The event featured a robust schedule of panel discussions, strategic briefings, and intensive, hands-on training workshops. Leaders from the Institute for Advanced Composites Manufacturing Innovation (IACMI) spoke about the organization and its workforce programs, including the Metallurgical Engineering Trades Apprenticeships and Learning (METAL) program.

METAL, led by IACMI – The Composites Institute®, and funded by the Department War’s Office of Industrial Base Policy, was created to revitalize American manufacturing through hands-on training in metalcasting and forging. Members of the 101st Airborne Battalion were able to participate in a METAL Bootcamp as part of the symposium.

Through K-12 workshops and university-led bootcamps METAL introduces students and career seekers to modern metalcasting and forging careers. Participants complete a free online training course before attending immersive, in-person bootcamps led by professional metallurgists and manufacturing experts.

How IACMI is Supporting the American Warfighter

On Wednesday, August 5th, the symposium focused on advanced manufacturing training in the age of Industry 4.0. Dr. Uday Vaidya, Chief Technical Officer at IACMI, and Andrew Pokelwaldt, Director of Education and Workforce Programs, spoke about the institute and its programs.

Andrew Pokelwaldt speaks with a soldier while observing the JAMS training session.

Vaidya provided an overview of the organization, originally funded by the Department of Energy, and its work on both civilian and defense projects. He spotlighted technology used to craft braided beams for construction, composite battlefield tourniquets, training rounds used for tanks, and new helmet tech. In his role at the University of Tennessee Knoxville, Vaidya also oversaw the METAL Bootcamp being offered to service members as part of JAMS.

During his presentation, Pokelwaldt, a Marine Corps veteran, underscored a stark reality facing the domestic manufacturing base and the military alike: “Ninety percent of durable manufacturing goods and critical manufacturing equipment is supported by these roles, and most of the time if anything is critical or involves precision, it’s going to take skilled engineers, skilled technicians, and skilled workers that can operate the equipment.”

He went on to note that even the most advanced equipment is rendered useless without a properly trained workforce. “A lot of the time it’s not the equipment, it’s the users. So if those people aren’t trained to deal with the advanced manufacturing equipment, that’s going to be a challenge, he said.”

Forging the New Workforce

Pokelwaldt detailed the success of the IACMI’s workforce programs:

America’s Cutting Edge (ACE) has impacted thousands over its five-year history. Combining free online courses with week-long, in-person bootcamps, ACE focuses on machining, composites, metrology, and advanced manufacturing. The goal is to get “people’s hands on that equipment,” said Pokelwaldt.

Pokelwaldt also highlighted the importance of the METAL program. “Casting and forging has been identified as an area that the United States does not have much capability compared to what it used to,” he explained. METAL is designed to bring domestic manufacturing back and increase existing capabilities in these vital areas. METAL is rapidly expanding nationwide to meet critical demand.

The presentation also addressed the long-term strategy for sustaining the manufacturing workforce. Pokelwaldt emphasized IACMI’s outreach efforts, recognizing that the “manufaturers of the future need early exposure to STEM concepts and basic manufacturing principles. “We start at a young age to give people basic manufacturing principles… and build all the way through,” he stated.

A surprising trend Pokelwaldt noted was that many intelligent and capable young adults entering these programs have never used basic hand tools. This lack of foundational experience makes hands-on training even more vital. “If they can’t even do that, they’ll struggle,” he said, referring to the basic mechanical adjustments often required on machinery.

By partnering with educational institutions and industry, IACMI is working to fill this pipeline, providing internships and apprenticeships that offer real-world experience. METAL’s upcoming K-12 mobile units are designed to generate interest in manufacturing early and give young people the hands-on experience many are missing.

A group of soldiers prepares sand molds during a training source.

Active duty service members participated in a METAL Bootcamp from the University of Tennessee Knoxville.

The METAL Investment Casting Bootcamp

The strategic discussions at JAMS were paired with practical application. During the symposium, service members from the 101st Airborne and visiting Marines participated in intensive workshops at the HAMMER (Hub for Advanced Manufacturing, Metalworking, Engineering, and Repair) Training Site.

Among the offerings was a METAL Bootcamp led by Amy Wheelock and Thomas Drye from the University of Tennessee, Knoxville. The course provided trainees with a comprehensive understanding of how to move a custom design from concept to a finished metal piece.

The workshop curriculum was rigorous and highly practical:

A service member pours molten tin into a sand mold.

Bootcamp participants made designs using CAD, made sand molds, and poured molten metal.

Day 1: An introduction to the METAL program and investment casting, followed by CAD instruction and pattern modeling.

Day 2: A deep dive into 3D printing and injection molding. Trainees learned slicing techniques, observed injection molding demonstrations, and prepared their 3D printed patterns.

Day 3: Focus shifted to sand casting and simulation, including spruce patterns, the burnout process, and a demonstration of Skuld Additive Manufacturing Evaporative Casting (AMEC).

Day 4: The core activity, melting metal and performing the investment casting process, followed by retrieving and finishing the cast components.

Day 5: An essential introduction to Non-Destructive Testing (NDT), where trainees performed ultrasound and dye penetrant testing on their finished parts to ensure quality and structural integrity.

The Future of Manufacturing at the Tactical Edge

JAMS highlighted the urgent need for agile, advanced manufacturing capabilities within the defense industrial base and on the battlefield. Programs like METAL are vital to ensuring that the nation’s warfighters and thenation’sindustrial base are prepared for the challenges of the future.

If you are interested in attending a METAL Bootcamp or want to learn more about a career in the foundry and forging industry, visit the METAL website today.

Highlights from AFS Industry 4.0 2026

“Companies need to know their destination before choosing their tech. If you don’t know where you’re going, any road will get you there,” said Jim Wetzel, co-founder of NxGen, quoting Alice in Wonderland.

Wetzel has been a leader in manufacturing for decades, and was a keynote speaker at the most recent AFS Industry 4.0 conference.

This strategic communication principle is the bedrock of successful Industry 4.0 adoption. Companies can’t simply plug in a new system and expect optimization without a clear blueprint of their desired business outcomes.

Wetzel cited a report from MIT that 95% of generative AI pilots at companies are failing.

The leading reason for these failures?

Lack of alignment to business outcomes.

“Know the value first,” Wetzel said, reiterating that understanding the business’ needs before making big spends on technology was key to successful implementation.

The 2026 American Foundry Society (AFS) Foundry Industry 4.0 Conference was held in Minneapolis on July 28-30. The METAL team was there to see firsthand the future of the foundry floor.

From AI integration to advanced robotics, the future of foundries is both high-tech and dependent on a skilled workforce.

METAL, led by IACMI – The Composites Institute®, and funded by the Department of War’s Office of Industrial Base Policy, was created to revitalize American manufacturing through hands-on training in metalcasting and forging. Finding workers was a recurring point of discussion amongst attendees and during the tour of the 3M CAM facility in Saint Paul, MN.

Through K-12 workshops and university bootcamps, METAL introduces students and career seekers to modern metalcasting and forging careers. Participants can complete METAL’s free online training course before attending immersive, in-person bootcamps led by professional metallurgists and manufacturing experts.

1. The Stakes Are Higher Than Ever

Todd Hutcheson, Director of Advance Iowa and the Center for Business Growth and Innovation at the University of Northern Iowa, provided a sobering look at the industrial landscape.

American metalcasting is at a crossroads.

Ninety percent of all manufactured goods contain castings, yet the number of U.S. casting plants has declined by 72 percent since 1991.

The path forward? Embracing technologies that bring smart manufacturing back to the U.S. while improving resiliency.

“Value comes from change when it enables new or improved capability and from stability when it preserves or better controls existing capability,” Hutcheson said. “Industry 4.0 implementation accomplishes both.”

Despite the decrease in facilities, Hutcherson noted the importance of casting and foundries to the economy. The industry supports nearly 800,000 jobs across the supply chain and is valued at over $50 billion.

Hutcheson also touched on how University of Northern Iowa (UNI), a METAL partner university, is tackling industry challenges. The school’s Metal Casting Center, Foundry 4.0 Center, and Center for Business Growth and Innovation work together to “engage students and staff in research and education.” UNI will soon begin offering METAL Bootcamps as part of this mission.

2. The (AI) Elephant in the Room

Artificial intelligence was a hot topic among speakers and exhibitors. Mike Lakas, Senior VP for IT at the American Foundry Society touched on everything from Large Language Models (LLMs) and transformers to the influx of Chat GPT-generated content. The core takeaway was separating practical utility from marketing buzz. The highlight of Lakas’ presentation was a comparison of outputs asking generative AI to produce an image. The difference between the initial image generated years ago and the video made this year was staggering and demonstrated a point he had made earlier: “We tend to overestimate progress in the short-term and underestimate it in the long run.”

Conor Keenan of Sinto America, who played a role in developing the new SMART Foundry at Purdue University, detailed how intelligent data tools are already making an impact. He explained that these tools are more than data collectors; they use advanced pattern recognition to drive real-time decision-making.

“When you get your data is just as important as getting the data itself,” he stated.

3. Who Let the Dogs Out?

A Humanoid robot wears a METAL ball cap.

SIR Robotics, an Italian company with offices in California, showed off their robot Luciano.

Attendees were treated to case studies showing how digital tools are already yielding massive ROI on the floor:

Spot the Robot Dog: Jacob Moreau showcased how a Boston Dynamics robot is performing over 120 autonomous inspections for a Toyota NA camshaft supplier.

“The bot paid for itself in ROI within 10 months,” he said.

Spot uses thermal imaging, LiDAR, and acoustic leak detection to monitor equipment across the 200,000 sq ft facility.

Precision Pouring: Operations Data Analytics Engineer Ellyn Neubauer described how optimizing furnace controls using pyrometer data has impacted Mercury Marine, which manages an incredible 1.6 million pounds of poured steel per year. The use of the two-color pyrometer system has enabled continuous indirect temperature feedback, leading to more controlled furnace melts.

4. At the Forefront of Cyber Security Compliance

The conversations around smart energy and cybersecurity are urgent. ECK Industries recently became the first foundry and one of the first 50 companies to achieve CMMC (Cybersecurity Maturity Model Certification) Level 2. This framework requires defense contractors to protect Controlled Unclassified Information (CUI) and applies to any company handling CUI in the DoW supply chain. This information can include drawings, specs and technical data, etc.

Aaron Hayon, Director of Technology and Security at Eck Industries, and Jeremy Mares, who manages federal accounts at Redspin, provided an overview of the CMMC guidelines and Eck’s journey to certification.

“Trying to be the first to do something within an industry is always challenging. It seems that every day we learn something new about how requirements should be interpreted, how the CMMC program continues to evolve, and how available tools can be leveraged more effectively,” noted Hayon of the process.

The Takeaway

A tour group looks on as a tour guide speaks in a manufacturing lab

AFS Attendees were able to tour the 3M CAM Lab in Saint Paul, MN.

For us at METAL, the AFS Foundry Industry 4.0 Conference is a clear signal that our mission has never been more vital.

The technological advancements showcased in Minneapolis, from autonomous robotic inspections to AI-driven process optimization, offer a definitive path forward for reversing the decline of U.S. casting and forging facilities.

However, this digital transformation cannot succeed without a workforce capable of executing it. By continuing to offer expert-designed online and hands-on training, as well as stackable credentials, METAL is actively equipping the next generation of metalcasting pros with the digital know-how and problem-solving skills required to bring the Industry 4.0 vision to life on the foundry floor.

Kayla Konieczny with Erie Bronze and Aluminum

Check out this episode of Industrial Talk featuring Kayla Konieczny with Erie Bronze and Aluminum.

Industrial Talk is onsite at Penn State and talking to Kayla Konieczny, Sales and Procurement Specialist at Erie Bronze & Aluminum about “Manufacturing careers”.

Scott Mackenzie introduces Elevotec, a company offering ERP, EAM, and business intelligence solutions, and highlights the Industrial Talk Podcast’s focus on industry innovations and professionals. Kayla Konieczny, from Erie Bronze, discusses her career path from the food and car industries to her current role in procurement and manufacturing. She emphasizes the importance of hands-on experience and the challenges of material sourcing, particularly the volatility of prices for metals like tin and aluminum. Kayla also highlights the need for more women in manufacturing due to their attention to detail and organizational skills. The conversation concludes with a call to support programs like Penn State’s METAL program to inspire the next generation of industrial leaders.

“We Need You”: Gen Z Finds Careers That Matter at Ashland Foundry & Machine Works

John Mingst grew up in Bethpage, New York, a manufacturing town shaped by its long history of military and aerospace innovation. He remembers family members talking about working on the Apollo lunar module, and Grumman aircraft known as “the cats” — the Hellcat, Wildcat and Tomcat — were all part of his community’s identity.

When it was time to choose a career, Mingst had no doubt he’d follow that legacy. Today, the 24-year-old engineer leads project management for the Navy’s Nuclear Propulsion Program at Ashland Foundry & Machine Works, LLC (AFMW), a Pennsylvania manufacturer that specializes in fully machined iron castings for defense and other critical industries.

“You could say it was in my blood,” Mingst said, “to work in the military aspect of industry.”

Mingst is part of a growing number of Generation Z pursuing careers in manufacturing and the skilled trades. METAL is fueling their momentum, helping more young people discover paths into metalcasting and forging through hands-on training.

John Mingst, 24, is a project manager supporting the Navy’s nuclear manufacturing needs at Ashland Foundry & Machine Works, LLC.

Gen Z Redefines Career Success

Gen Z has officially overtaken Baby Boomers in the workforce, and more young adults are expanding their definition of desirable careers to include manufacturing and skilled trades.

In 2024, economists found that nearly 25% of new hires in trade industries were 18 to 25 years old. Even with this growing interest, U.S. manufacturers could have 3.8 million positions to fill by 2033 without enough workers for nearly half the roles.

“You’ll walk through just about any domestic foundry and see a lot of old gray-haired guys like me, and you’re missing a lot of younger people,” said Tony Badamo, AFMW vice president of sales, marketing and engineering. “We need to play catch up.”

As President Donald J. Trump prioritizes reindustrialization, manufacturers need workers with advanced skills to cast and forge parts for fighter jets, naval ships, aircraft turbines, heavy equipment and nuclear energy.

“There’s a lot of growth going on in nuclear power,” Badamo explained.

The stakes are especially high for the U.S. Navy’s Nuclear Propulsion Program, which maintains the nuclear-powered aircraft carriers and submarines that protect our nation. With ballistic missile submarine production expanding and shipbuilding and repair years behind schedule, foundries must be ready to deliver the castings the Navy depends on.

“I’m going to borrow a line from Uncle Sam: We need you,” Badamo said.

Building the Foundry’s Talent Pipeline

Led by IACMI – The Composites Institute®, METAL is accelerating the development of a highly-skilled metal workforce. Through hands-on bootcamps, K-12 workshops, free online training and apprenticeship support, METAL helps students and career seekers discover opportunities in the metal industry and gain the foundational experience to pursue them.

“A skilled engineer, in my opinion, is somebody that can walk in the foundry on day one and add value,” said Dr. Paul C. Lynch, an associate professor of industrial engineering who leads METAL’s bootcamps at Penn State Behrend. “How do you get there? It’s internships and real-world experiences working in the industry.”

AFMW is helping build that talent pipeline through research, internships and recruitment in partnership with Penn State Behrend. The foundry also sends new engineers to METAL’s bootcamps, where they can expand their knowledge of modern metalcasting and forging processes.

“METAL is a nice opportunity to give a young emerging engineer who’s never been in the industry a broad look at the foundry industry,” Badamo said.

Ashland Foundry & Machine Works, LLC, a Pennsylvania iron manufacturer, partners with Penn State Behrend and METAL to give students and career seekers hands-on training and build stronger pathways to metalcasting and forging careers.

The Impact of Real-World Experience

Mingst had his first industry experience while he was in engineering school. He interned at TTM Technologies, a leader in advanced defense and aerospace communication, where he worked on microchips. Although the scale and processes differed from foundry work, Mingst said the internship provided him with the understanding to support the military’s manufacturing needs.

“TTM builds the communication systems for Air Force One and all the modern F-35 fighter jets,” Mingst explained. “I really got exposed to how things work with the government and the military and how important it is, which I brought to my first full-time position.”

After graduating from SUNY Polytechnic Institute, Mingst followed his curiosity about machining to a process engineer position with defense and high-tech manufacturer PRL Inc. It was his first time in a foundry, and watching red-hot liquid metal cool into solid parts changed Mingst’s future. He was hooked.

“I fell in love with getting down to the chemistry of the metals and the pouring practices,” he recalled. “That’s what led me down this path of ‘I want to continue to do this.’”

When an engineering position opened at AFMW, Mingst didn’t need much convincing to join the team. Badamo described the foundry as the manufacturing mothership for defense clients, with opportunities to help lead production of advanced metal products. Three months after Mingst joined AFMW as a project engineer, Badamo promoted him to program manager.

“We knew that we needed to shore up our talent pool,” Badamo explained. “There’s a real high demand for quality engineering support when you produce castings for the Navy’s Nuclear Program.”

For Jack Nemshick, a 21-year-old mechanical engineering senior at Penn State, his first day at AFMW’s foundry was eye-opening.

“When I first got in, there was a lot more to it than I thought there would be. I thought they just pour the metal and then shake it out,” Nemshick said. “But they do pretty much everything from start to the finish, and that was really interesting to me.”

As an intern, Nemshick spent his summer learning heat treatment processes, researching material microstructures, and preparing a presentation for the Steel Founders’ Society of America.

“We offer an immersive experience,” Badamo said. Whether training entry-level engineers, metal workers or student interns, AFMW prioritizes workforce development for industry newcomers.

“The first day you walk in the operation, you either say to yourself, ‘There’s no way I want to be here,’ or you’re like, ‘Hell yes, I’m all about this,’” Badamo said with a laugh.

Regardless of previous experience, Badamo believes the foundry is the best place to learn.

“We just need people who want to come and work, who want to make something with their hands,” he said. “That’s first and foremost, because we’ll teach it. We’ll show you what you need to do.”

Jack Nemshick, 21, is a mechanical engineering senior at Penn State University who had his first hands-on foundry experience as a summer intern at Ashland Foundry & Machine Works, LLC.

Closing Metal’s Skills Gap

Thanks to METAL, students and potential metal workers don’t need to wait until their first day on the job to discover if they’re a good fit for the metal industry.

METAL’s metallurgical bootcamps provide up to a week of hands-on metalcasting and forging experience at university foundries nationwide. Participants begin with the fundamentals of the casting process, designing molds and testing pour simulations with CAD software. They also study quality tests that metallurgists use to evaluate bridge beams, aircraft components and products people depend on every day.

Before the bootcamp ends, participants suit up for the foundry. Clad from head to toe in fire-resistant gear, each one learns how to guide a ladle filled with molten metal and complete a safe pour. They leave with pieces they cast or forged themselves and a clearer picture of where these skills can take them.

“We need people to recognize there are career opportunities here,” Badamo explained.

AFMW recently collaborated with METAL on a virtual reality tour of its foundry for job candidates and bootcamp participants. The video offers a behind-the-scenes look at what it’s like to be a pattern maker, molder, operator, cleaning area worker, and quality inspector. METAL plans to share the tour with middle school students during week-long K-12 workshops, where they’ll also practice casting with chocolate and aluminum.

“If you don’t see it, you just have no idea what you’re getting into and you wouldn’t know if it’s a career you’d want,” said Crystal Bentley, communications and public affairs manager at IACMI. “It’s important to have visuals like this on the front and the back end of training.”

Mingst can’t imagine a more exciting career choice, and he’s following his dream: contributing to mission-critical work the nation depends on.

“You learn a lot coming right out of school very quickly in this industry,” Mingst said, adding, “this industry is going to stay in the United States. It has to, and the foundries are still strong.”

Ashland Foundry & Machine Works produces and tests iron castings weighing up to 10,000 pounds for naval vessels, defense systems and other critical applications.

Ready to forge America’s future? 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.

METAL is 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).

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METAL announces four new partnerships to advance workforce training in metalworking and manufacturing

University of Wisconsin-Madison College of Engineering, University of Northern Iowa, Cleveland State University and Texas State University strengthen growing national network of METAL hubs

KNOXVILLE, Tenn. (August 3, 2026) – The Metallurgical Engineering Trades Apprenticeship & Learning (METAL) program, led by IACMI – The Composites Institute®, is proud to announce four new partnerships to enhance and scale up industry-driven training opportunities for current and prospective metalworking and manufacturing professionals: the University of Wisconsin-Madison College of Engineering, the University of Northern Iowa, Cleveland State University and Texas State University. Supported through funding by the Department of War’s (DoW) Office of Industrial Base Policy, METAL strengthens and diversifies the U.S. metal manufacturing workforce, focusing on casting and forging.

The University of Wisconsin-Madison (UW-Madison) College of Engineering, the University of Northern Iowa (UNI), Cleveland State University (CSU), and Texas State University (TXST) will implement METAL’s nationally recognized curriculum in their programs, beginning with a combination of online training and immersive in-person bootcamps held in manufacturing labs equipped for metal melting, heat treatment and machining capabilities.

In addition to adult training, most of these programs will lead outreach efforts for K–12 students by offering workshops and partnering with high schools and other local and regional schools to spark early interest in metallurgical careers.

“METAL is proud to partner with the University of Wisconsin-Madison College of Engineering, the University of Northern Iowa, Cleveland State University, and Texas State University to strengthen the metalworking and manufacturing talent pipeline,” said Michael Kubacki, METAL Program Director at IACMI. “By investing in hands-on training and skill development, we’re not only helping individuals build successful futures – we’re contributing to the next generation of manufacturing excellence.”

Upon completing online and in-person bootcamp training, participants at each METAL partner may enter a stacked curriculum offering a menu of specialized training opportunities within METAL, allowing participants to tailor their learning experience, including an enhanced focus on automation in the casting and forging industry.

“We are excited to have the UW-Madison College of Engineering participate in this manufacturing workforce development program and to partner with the UW-Madison School of Education to leverage the Art Department’s foundry,” said Frank Pfefferkorn, a professor of mechanical engineering who is leading the METAL program at UW-Madison. “Inspiring people to pursue careers in metal casting and forging continues a long-standing tradition in the state of Wisconsin, which has the most foundries per capita of any state in the U.S. Anyone who is interested can participate in the hands-on experiential bootcamps – no prior knowledge or experience is required.”

“Metal casting has been a cornerstone of the University of Northern Iowa’s academic programs for generations, and this partnership allows us to introduce more students to the tremendous opportunities within the industry,” said Nathaniel Bryant, associate director of the UNI Metal Casting Center. “We are excited and proud to join the METAL network and provide the workforce training that will help meet the evolving needs of manufacturers across Iowa and the nation.”

“At the CSU Washkewicz College of Engineering, we believe the best engineering education combines a strong academic foundation with meaningful hands-on learning,” said Tushar Borkar, professor of Mechanical Engineering at CSU. “Through our partnership with METAL, students and industry professionals will gain practical experience in advanced manufacturing and forging technologies, helping build the highly skilled workforce needed to strengthen Northeast Ohio’s manufacturing ecosystem and support the future of American manufacturing.”

“We are very excited to join and contribute to the METAL network and to be able to provide these high-quality training opportunities to our students and the people of the state of Texas,” said Luis Trueba, Ph.D., an associate professor in the Department of Engineering Technology at TXST.

UW-Madison College of Engineering, UNI, CSU and TXST’s partnerships with METAL include plans to:

Provide online training, progressing to hands-on, in-person bootcamps conducted within manufacturing labs, equipped with metal melting, heat treatment and machining capabilities
Execute multiple in-person bootcamps for program participants throughout the course of their tenure
Hold numerous workshops for K-12 students (select sites)
Foster collaborations with local high schools and community colleges. This strategic partnership will focus on integrating METAL training into their educational curriculum, enriching opportunities for students interested in metalworking and manufacturing
Host metalworking job fairs to provide a platform for student recruitment (select sites)
Establish academic credit for secondary and post-secondary students and non-credit pathways including courses that can be applied to micro credentials, industry certifications, apprenticeships and degree tracks. The effort ensures alignment with industry standards while providing students with recognized certifications and future educational opportunities in metallurgy.

Last month, IACMI announced plans to expand METAL and America’s Cutting Edge (ACE), another workforce development program focused on machining and manufacturing, to 53 new locations at universities, colleges and trade schools by 2030, bringing the total number of sites to more than 100. Additionally, IACMI will introduce new initiatives to engage over 50,000 K-12 students and provide hundreds of internship opportunities.

UW-Madison College of Engineering, UNI, CSU, and TXST’s additions to the METAL network strengthen a growing national network of METAL hubs, including the University of Alabama at Birmingham, The Ohio State University, Pennsylvania State University, the University of Tennessee, Knoxville, Tennessee Tech, Michigan Technological University, California State Polytechnic University, Pomona, NC State, Purdue University, and Georgia Southern University. Together, these institutions are revitalizing American manufacturing by delivering responsive, scalable and sustainable workforce development programs.

For more information about METAL at UW-Madison College of Engineering, UNI, CSU and/or TXST, please contact:

Sarah Pope
Email: Sarah@piper-communications.com
Phone: 865-329-0553

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

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

About the University of Northern Iowa

The University of Northern Iowa, located in Cedar Falls, Iowa, prepares students for success through personalized learning, hands-on experiences and an education that delivers exceptional value. Serving more than 9,000 students and offering more than 160 areas of study, UNI combines nationally recognized academic programs with the support and real-world opportunities that help students graduate confident, career-ready and prepared to make an impact.

About the University of Northern Iowa’s Metal Casting Center

The University of Northern Iowa’s Metal Casting Center (MCC) is in the Applied Engineering Building on UNI’s main campus in Cedar Falls, Iowa. As leaders in independent research specializing in metal casting materials, processes and technology, the UNI Metal Casting Center focuses on materials research, metal manufacturing and foundry education.

About Cleveland State University

Founded in 1964, Cleveland State University is a public research institution located in the heart of downtown Cleveland with 13,000-plus students, eight colleges and more than 175 academic programs. CSU leverages its unique location and strategic partnerships to equip learners with knowledge and future-ready skills for infinite opportunities. Through innovative research, dedicated service and exceptional talent, CSU addresses the evolving needs of Northeast Ohio. Find more information at csuohio.edu.

About Texas State University

Founded in 1899, Texas State University is among the largest universities in Texas with an enrollment of more than 44,000 students on campuses in San Marcos and Round Rock. Texas State’s 251,000-plus alumni are a powerful force in serving the economic workforce needs of Texas and throughout the world.

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