Picture this: Molten metal is flowing, sparks are flying, and a group of 18- to 30-year-olds step into the foundry to keep this vital industry moving forward. These aren’t the factory workers of decades past—these folks are crafting fire hydrants and water main fittings with a mix of traditional skill and modern technology today. But how do we prepare this next generation for a trade that’s ancient yet always evolving? It’s about combining computer-based training (CBT)—think screens and simulations—with real, hands-on experience. Let’s take a closer look.

Screens Before Sparks: CBT in Action

Today’s foundry workers aren’t just strong—they’re tech-savvy and quick to adapt. The 18- to 30-year-old age group grew up with smart phones and instant access to information. They’re comfortable with technology and thrive on interaction, which makes them a great fit for a training approach that blends digital tools with practical work. Computer-based training builds their knowledge, while hands-on time ensures they can apply it. Together, these methods are shaping a skilled, future-ready workforce.

At Tyler Union, we have adopted a CBT approach to safety and operational training for the plant-floor workforce, including forklift operation, lockout/tagout, crane operation, grinding, hearing conservation, and more. Each segment is followed by a hands-on training experience. 

The result has been a positive new pattern: 

(1) Younger employees engage with the material and absorb it well––this is how they learn thanks to the distance learning that became the norm since 2020.
(2) An extension of that norm is the improved end-of-course test scores we’re seeing. One reason: They can view the content multiple times if they want to.

In our new protocol over the last eight months or so, we train groups of 10–12 people at a time, and the entire computer portion of the safety program can be completed in two-and-a-half days. Offered in English, Spanish, and French/Canadian through a product called Brainier, the training is exactly the same and provides complete, consistent information every time––although I am a veteran in-person trainer, I realize that sometimes live trainings can occasionally omit important details.

Computer training has tremendous cost and safety advantages, too.

Here’s what I see when I look at a new trainee sitting at a computer: On the screen, a virtual mold is ready for molten metal. The trainee adjusts the temperature, changes the alloy mix, and sees the results in a 3D simulation. If they make a mistake, no problem—the system points it out, explains why the casting failed, and lets them try again. No materials are wasted, and no one gets hurt; it’s all about learning.

AFS offers a program called Foundry E-Learning, which is an excellent example of this approach. The available curricula covers a range of topics to teach the basics of metalwork and prepare trainees for the real thing. Studies show CBT can shorten learning time by up to 30%, which is critical as experienced workers retire from our industry—we need fresh talent fast.

Hands-On: Where It All Comes Together

No computer can fully capture the heat of a furnace or the feel of a ladle. That’s where hands-on training steps in. 
On the foundry floor, young workers at our company turn digital lessons into real skills with guidance from experienced mentors. They pour metal into molds and tackle challenges as they arise. It’s where theory meets reality.
Many programs pair CBT with apprenticeships, moving trainees through tasks like melting or finishing. This builds a range of abilities, which is key in today’s foundries. 

For a generation sometimes seen as less connected to physical work, creating something tangible brings a sense of accomplishment and purpose––whether it’s a fire hydrant or water main fitting like those we make, or a vital component from the myriad industries AFS member foundries serve. It’s important to tie the daily details to the big picture of how their work contributes to critical aspects of contemporary life, including all modern conveniences and every industry that directly touches their lives.

Blending Old and New

The combination of CBT and hands-on training isn’t just helping the newcomers—it’s transforming the metalcasting industry. 

Foundries are adopting automation and 3D printing, so workers need to handle both manual tasks and technology. Training them this way ensures the metalcasting trade stays strong in a modern world. 

At Tyler Union, we partner with a local community college to offer internships for those studying relevant metal fields, giving students a chance to work alongside our team members and learn the ropes while still in school.

There are hurdles, though. 

Computer-based training programs require investment in software and subscriptions, which can be tough for smaller foundries. 

There’s another sticking point. Some young people hesitate, turned off by the physical demands of foundry work or the idea that these jobs aren’t glamorous. 

Our industry is responding with partnerships with community colleges to highlight the opportunities foundry work offers.

A Bright, Molten Future

As one chapter of foundry work closes, another begins. The 18- to 30-year-olds entering this field aren’t just replacing others—they’re pushing it forward. 

With computer-based training, they’re mastering metalwork quickly. With hands-on experience, they’re keeping a centuries-old craft alive. 

One example: Twenty-two-year-old Sam is a new hire at Tyler Union. His first task was learning lockout/tagout—safety steps to shut down machines before maintenance. He started with a CBT module on his laptop, walking through the principles of lockout/tagout. Then, he practiced following the procedures in a simulated environment until he had it down. 

Only after that did he meet his leadman and supervisor on the foundry floor, where they guided him through the real thing. By then, Sam wasn’t just following instructions––he knew why each step mattered. 

The combination of computer-based training plus hands-on experiences is a training approach that is not only going to help this industry endure––but thrive.