METAL Meets Mines: From Under the Earth to the Open Road

METAL Bootcamp graduates are ready to enter the casting and forging industry. Our incredible partners offer these bootcamps at a growing number of Universities and industry sites across the country. With new partner sites coming online across the country, we’re reaching more people than ever. New METAL partner Colorado School of Mines (Mines) will allow us to take our hands-on bootcamps even further with a new mobile STEM learning environment. Mines also granted us access to their Edgar Experimental Mine, allowing us to film the first footage for an exciting new project.

Hitting the Road

The “MMM” (Mobile METAL Manufacturing) unit is an upcoming transportable learning center being developed by MINES. The 18-wheeler based training site will allow mines to take METAL bootcamps across the western U.S. and beyond. While other METAL mobile units focus on K-12 outreach, the MMM offers the same experience found at METAL sites across the country.

“We have been amazed by the level of interest generated by the Mobile METAL Manufacturing training 18-wheeler. Industry partners and educational institutions alike immediately recognize the value of bringing advanced, hands-on manufacturing training directly to their locations,” says Mines METAL Project Lead, Professor Terry Lowe PhD.

The trailer will offer a full suite of equipment, allowing the Mines team to bring the full bootcamp experience to schools, events, and industry sites. This includes furnaces and sand for melting and pouring molten metal. A machine shop section will allow participants to process their completed cast and forged pieces, while microscopes, tensile testers, and other equipment will be used to cover the testing phase.

From Earth to Orbit (or aerospace, or ocean)

Mines offers courses in bladesmithing, has competed several times in the Cast In Steel competition, and can cast and forge steel in its university foundry. There’s a reason, however, that the school is called Colorado School of Mines. For over a century, Mines has operated the Edgar Experimental Mine, doing far more than just training miners. The former gold and silver mine is used to train rescue teams, conduct research for quantum physics, and serves as a living museum of Colorado’s mining history.

The Edgar Mine has been used for teaching for over a century.

As part of METAL’s efforts to promote the importance of the casting and forging industry and fill the coming skills gap, the METAL team began developing a new documentary-style project detailing the life of metal from the time it’s dug out of the earth to the finished product. Dr. Lowe and Mine Forman Clint Dattel provided METAL with access to film inside the mine, kickstarting the project.

“It was a thrill to film in the Edgar Mine and around the Mines campus. This project will go a long way toward showing the importance of METAL and the need to fill so many jobs in and around the casting and forging industry,” said METAL Communications Specialist Jeffery Ledington.

“Earth to Orbit” (final name TBD) is an exciting opportunity to highlight the many jobs metal touches, and that need to be filled. Be on the lookout!

Josh Brown and Steven Fedell with METAL for America

Check out this episode of Industrial Talk featuring Josh Brown and Steven Fedell with Penn State University METAL Program.

Industrial Talk is onsite at Penn State and talking to Josh Brown and Steven Fedell with Penn State University METAL Program about “Why they are passionate about the future”..

Forging the Future: Robotics and METAL

Heavy hammers. High heat. Glowing metal. These are all images that come to mind when one pictures a foundry. While the heat and the molten materials remain central, the modern foundry floor is undergoing a massive technological transformation, and METAL is staying on top of the game. Our partners, including the University of Tennessee Knoxville, are bringing advanced robotics directly into the educational space. Bootcamp and workshop participants are getting a firsthand look at how smart manufacturing is reshaping the trades. It is no longer just about melting and pouring; it is about precision, safety, and efficiency.

Heavy Industry and High Tech

A worker moves cast iron bathtubs using a special machine.

At the Kohler Foundry in Kohler, WI, high tech machines allow workers to move heavy cast iron tubs safely and with ease.

When participants step into a modern metal workshop, they see advanced robotic arms operating just feet away from traditional sand casting tables and investment casting stations. This pairing of the old and the new demonstrates the real-world applications of automation in manufacturing. Today’s industry relies heavily on automation to handle repetitive, dangerous, or highly precise tasks. By integrating these dynamic machines into the learning environment, bootcamps provide a comprehensive, 360-degree view of modern production pipelines.

Precision and Durability on the Foundry Floor

Industrial-strength heavy lifters, utilized in large-scale factory settings, are built to withstand the intense rigors of heavy industry. During induction forging demonstrations, these robust robotic arms handle the high-stress, high-heat tasks.

Paul, a UTK computer science student working on the foundry robots, explained the specific advantages of their UR12e model: “The UR12e on the other hand is actually used in industry as a factory robot, so that’s what we use for the induction furnace. It’s a little more durable, it can take more stress and stuff, and it’s also a lot easier to program.”

Two students pose with a robotic arm in a laboratory setting.

Tennessee students Paul and Vishnu work with the robotics used for METAL workshops and bootcamps.

These industrial machines are programmed to grip cylindrical metal pucks and precisely manage their thermal cycles. Describing the automation of this intense environment, Paul says they will “heat them up till they’re like orange, almost white-hot, and then we put them in a hydraulic press and we stamp the METAL logo into them.”

After the stamping process, the robotic arms smoothly transition metal into a cooling water bath. “We also have it dunk the puck in water to cool it off afterward so you can control how long it swirls,” Paul notes, ensuring the metallurgical properties of the token or tool are properly set without ever risking human burns.

In contrast to heavy-duty factory arms, smaller precision robots are deployed for tasks requiring delicate, highly accurate movements. Utilizing advanced camera systems and artificial intelligence, these robots perform dynamic location and sorting functions.

Vishnu, another researcher working on robotics, explains that the system uses a “machine learning algorithm to take a picture of it, identify the shapes within the picture, and then set those as positions for it to come pick up and do stuff with.”

This level of precision requires meticulous calibration to ensure the robots function correctly. Because some colors naturally lack contrast in a factory setting, the team has to adapt the materials for the robot’s optical sensors. “We cover them with white so it has higher contrast; it’s easier for the robot to see,” Paul explains, highlighting the real-world troubleshooting required to make automation seamless.

Enhancing Safety Without Replacing the Artisan

A common misconception surrounding industrial automation is the fear of human obsolescence. However, the core philosophy demonstrated in these technical workshops is that robotics are implemented to enhance human capability, not replace it. Introducing a robotic arm to a blistering induction furnace has an incredibly straightforward benefit: operator safety.

A metal cylinder handled by a robotic arm and stamped with the METAL logo.

By delegating the most dangerous and physically demanding steps to machines, human workers are shielded from extreme temperatures, hazardous fumes, and repetitive motion injuries.

Paul perfectly summarized this ethos when discussing the robotic programming: “The idea is not to take the job from a human but to give a human greater control and safety over the process.” Consequently, the human element shifts from brute force to high-level process management. An operator working alongside a robotic arm is making critical decisions, controlling parameters via a tablet, and ensuring stringent quality control. The artisan’s deep knowledge of metallurgy is more critical than ever; the robot simply serves as a highly advanced tool that executes the artisan’s commands with unwavering consistency.

Training the Next Generation of Innovators

Ultimately, the inclusion of robotics in metal bootcamps serves as a critical bridge for the future workforce. Engaging with these technologies early on demystifies the programming, calibration, and maintenance of industrial machines. When students and participants adjust a time parameter on a tablet and immediately watch a robotic arm adapt its workflow in real-time, the advanced concepts of smart manufacturing become highly accessible.

The skills honed in these workshops go far beyond basic metalworking or simple casting. Participants leave with a foundational understanding of integrated manufacturing systems, machine learning applications in quality control, and the strict safety protocols required in automated environments. By striking this balance between traditional craftsmanship and next-generation technology, the industry is forging a smarter, safer, and incredibly innovative future.

How Sarah Jordan and Skuld are Reshaping Manufacturing and the Modern Workforce

Manufacturing has always been about making things. For Sarah Jordan, CEO and co-founder of Skuld LLC, the allure of the foundry began early. Growing up with a father who worked as a ceramics engineer, Jordan thought she’d be following directly in his footsteps. Instead, working in steel mills and foundries sparked a deep appreciation for metallurgy.

SkuldLLC Co-Founder and CEO Sarah Jordan.

“I always liked making things, and one of the fun things about being in a foundry is you get to make something tangible,” she said.

The Founder

With an extensive background that includes degrees in Metallurgical Engineering and Materials Science from The Ohio State University, an MBA from Carnegie Mellon, and ongoing PhD research at Worcester Polytechnic Institute, Jordan is steering her company toward an ambitious future. Skuld is actively merging the proven reliability of lost-foam investment casting with the cutting-edge flexibility of polymer 3D printing.

Traditional lost foam casting has long been reserved for extremely high-volume production. The sheer cost of traditional tooling can range from $150,000 to a couple of million dollars per part number. Jordan and her team saw 3D printing as a way to rethink the equation entirely.

“If you don’t need tooling, that seems like a better way to make small-volume things,” Jordan explained regarding the thought behind their innovation. Jordan notes that their technology is significantly faster than traditional investment casting, more accurate than sand casting, and much cheaper than relying solely on 3D printing. “It also allows you to have geometries that might not otherwise be feasible,” she added.

At the recent Joint Advanced Manufacturing Symposium at Fort Campbell, Skuld LLC put on a demo as part of the METAL Investment Casting Bootcamp. They arrived with a pre-printed cluster and gating system, walking trainees through the compaction process hands-on. By the end of the demonstration, they had melted aluminum right in the training bay and poured small army soldier statues.

Aluminum figure cast during the Skuld LLC demo at JAMS

Casting the Workforce

Technological innovation is only half the battle in modern manufacturing. The other half is ensuring a trained workforce is ready for the 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. 

Like many organizations in the manufacturing sector, Skuld LLC is facing significant workforce development hurdles. The company is growing rapidly and is on track to double in size this year alone. This kind of explosive growth highlights a critical gap in the industry METAL aims to fill: a distinct lack of experience on the floor.

“A lot of apprentice programs assume you have experienced mentors available, but if your most experienced people only have two years of experience, no one is really equipped to train,” Jordan says.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, allowing them to pass on their expertise to the next generation.

A bootcamp participant pours molten metal by hand.

Jaidyn from Skuld LLC pouring metal as part of the Ohio State bootcamp.

For Jordan, engaging with initiatives like METAL is a vital part of the solution. ‘Programs like this are great, especially for people who don’t do the hands-on pouring every day, like lab technicians, to get a better understanding of the technical side,” she said.

Following Rosie’s Footsteps

Overcoming the foundry industry’s historical workforce demographics requires highly creative communication strategies. The foundry space is notoriously male-dominated, but Skuld LLC has proven that a simple shift in language can open the floodgates to new talent. When the company advertised an open assembly position, Jordan decided to change the job title to see what would happen.

“I advertised an assembly job as a ‘Crafter,'” she recalled. “In two days, I got 80 applicants, and ninety percent were women, which is shocking for a foundry job. Sometimes it’s just about the words you use,”she stated.

Jordan continues to push boundaries in the industry. When asked where she saw Skuld LLC in five years, she stated, “We think we will have several facilities. Right now we’re developing capabilities around heat-treating fixtures. We’ve developed the ability to cast steel in lost foam, so we’re looking at parts that are painful to machine.” Skuld LLC is the fourth company Jordan has founded, plus starting a chapter of Women in 3D Printing.

“Just always keep on learning,” Jordan advises young folks. “The jobs you might end up in might not even exist yet, so you have to be open to new experiences.”

The Truth About Manufacturing Careers (Part 2) | IACMI’s Mike Kubacki and Elliot Keas

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

Peter Parsons wraps up his two-part conversation with Mike Kubacki and Elliot Keas of IACMI, digging into the perception problem manufacturing still faces with parents and students alike. Elliot and Mike talk through why so many people still picture manufacturing as dangerous and dirty, and how technology and innovation have reshaped what these environments actually look like today. The conversation also covers the different tiers of skill development in a modern facility, why apprenticeships matter for knowledge transfer, and how IACMI is partnering with veterans groups and job boards to connect people directly with industry. Mike and Elliot close things out by sharing their 10-year vision for the program, from expanding westward to building industry confidence in US manufacturing for the long term.

Andy Bomberger with METAL and Bomberger Industry Graphics

Check out this episode of Industrial Talk featuring Andy Bomberger with METAL and Bomberger Industry Graphics.

Industrial Talk is onsite at Penn State and talking to Andy Bomberger with Penn State University METAL Program about “Hands on manufacturing and foundry experience”.

The Industrial Talk podcast episode with Andy Bomberger describes nearly 29 years in foundry engineering, including work with steel, ceramics, polymers, machining, casting, and roughly 150–200 alloys.

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.

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

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