Apprenticeships Strengthen the U.S. Industrial Workforce

On National Apprenticeship Day, Metallurgical Engineering Trades Apprenticeship & Learning (METAL) recognizes the powerful impact of apprenticeships in addressing workforce gaps and supporting the U.S. defense and industrial bases.

The need to fill major gaps in the U.S. defense workforce is critical. Between now and 2028, the U.S. defense industrial base is projected to require at least 122,000 additional skilled professionals, including shipbuilders, engineers and others in critical roles supporting the Department of Defense

As defense manufacturing competes with other sectors for these critical workers, failure to meet the growing demand for skilled professionals could exacerbate vulnerabilities within the defense industrial base and the U.S. manufacturing economy.

Photo courtesy of Scot Forge

Training Partnerships Drive Success

METAL, led by IACMI – The Composites Institute, has a strategic partnership with Jobs for the Future (JFF) to provide apprenticeship opportunities that strengthen the nation’s metalcasting workforce while supporting the security and sustainability of America’s defense and manufacturing industrial bases.

METAL also provides consulting services, connections to funding opportunities and apprenticeship curriculum for companies to create custom training and on-the-job learning experiences. 

A good example of this is Goodwin Engineering Training Company. Goodwin partnered with METAL to share their highly successful apprenticeship model and curriculum to address critical skill gaps in the metal manufacturing workforce – their model is “a radical, new approach needed to raise the skill level of the individual worker to the standard that they required for future growth” said Natalie Jellyman, Goodwin Apprenticeship Manager.

By combining METAL’s workforce development mission with Goodwin’s proven training expertise, our partnership has delivered a specialized curriculum that integrates classroom instruction with practical, industry-relevant experience.

The curriculum can be easily adopted by companies that want to implement a turn-key apprenticeship program at no charge. In some cases, incentive funding is available to launch the new program. 

“We can learn so much from textbooks, from word of mouth,” said Lee McCue, Teacher at Goodwin Engineering Training Center, “But actually doing the job itself, and putting that knowledge into practice is where you find your feet and find those experiences.”

Apprenticeship programs, like the one at Goodwin, tackle workforce shortages, strengthen national security, boost U.S. economic competitiveness and build lasting career pathways in U.S. manufacturing.

Apprenticeships in Action

You can see the impact of apprenticeships in action at  CWC Textron, a leading manufacturer of high-quality castings for the automotive and industrial sectors.

CWC Textron’s apprenticeship pipeline provides apprentices with skills in machine repair, millwrighting and electrician apprenticeships. 

“By investing in apprenticeships, companies can support the development of individual careers and secure their future and the industry’s future,” said Holly Rolewicz, apprenticeship program lead for CWC Textron. “These trades are vital to our success, particularly in maintaining a foundry that has been operational for 117 years and relies on aging equipment.” 

Apprentices from CWC Textron

 

For more information on apprenticeship opportunities and curriculum development, connect with Lucinda Curry at lcurry@iacmi.org.

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

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

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

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

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

Meet Ianto Woolridge

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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

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

Virtual Reality Meets Metallurgy: The Future of Defense Training is Here

To address the growing need for skilled workers in the U.S. industrial base, the Metallurgical Engineering Trades Apprenticeship & Learning (METAL) program collaborates with universities to offer immersive bootcamps that equip participants with essential skills in metallurgy and manufacturing. One unique offering during these bootcamps is virtual reality-based foundry tours.

The tours complement the bootcamps’ hands-on training in critical skill areas like casting, sandblasting, and forging metals. This fusion of traditional craftsmanship and modern innovation ensures that graduates are well-prepared to contribute to advancing national defense and other critical sectors.​

Bringing Advanced Manufacturing to Life Through VR

The University of Tennessee and IACMI developed the virtual reality modules to enhance STEM education by immersing users in advanced composites manufacturing. Modules cover processes like carbon fiber production, sheet molding compound, extrusion, long fiber thermoplastic production, extrusion-compression molding, injection molding, pultrusion, and roll forming.

Virtual Reality

Students view metal casting through virtual reality at a foundry in Erie, Pennsylvania.

Uday Vaidya, Chief Technology Officer at IACMI, said these virtual reality modules are especially vital to provide immersive learning experiences and generate students’ interest in the metallurgical field.

“The virtual reality foundry is a very powerful one, not all K-12 students have the time to go to the foundry, ” said Vaidya.” “By viewing it on VR, it’s literally like being there. You’re going to basically see things like you’re on the floor, watching metal pour, big presses coming down on blocks of hot metal, you can almost feel the effects of the temperature and pressure. There’s nothing like experiencing it as close to the real world as possible.”

Virtual Reality Foundry

Uday Vaidya, Chief Technology Officer at IACMI, demonstrates virtual reality modules at a foundry in Erie, Pennsylvania.

Led by IACMI–The Composites Institute, METAL addresses critical workforce shortages in the U.S. casting and forging industry. Between now and 2028, the defense industrial base is projected to require at least 122,000 more professionals, including shipbuilders, engineers, and other essential roles supporting the Department of Defense. A shortfall in meeting this demand could pose a serious risk to the strength and security of U.S. national defense.

Vaidya said he’s incredibly grateful to the Department of Defense for funding METAL initiatives and hopes programs like these can support DOD and IACMI’s goal of reaching up to 100,000 students.

Learn more about METAL’s mission and our free online training here.