The foundry industry presents unique challenges that textbooks simply cannot teach. When young engineers enter this field, they often arrive with solid theoretical knowledge but lack understanding of the real-world variables that dictate casting quality, cost, and delivery. This knowledge gap between classroom theory and shop-floor reality has profound implications—not just for individual career success, but for the competitiveness of the entire North American casting industry.

Drawing from Frank Hoyson’s 44-year journey from journeyman coremaker to global casting quality executive, and Dr. Sudesh Kannan’s (Dr. K) international metallurgical consulting experience across five continents, this article distills hard-won lessons into actionable guidance for the next generation of foundry professionals.

Foundational Lessons: 
Building the Right Mindset

Every foundry is different. This fundamental truth shapes every problem-solving approach in the casting industry. Just because several foundries produce identical castings doesn’t mean they use the same steps and processes. This reality became clear early in my apprenticeship at Hodge Foundry, where Hoyson completed a state-certified 8,000-hour program to become a journeyman coremaker.

The apprenticeship proved transformative. Working in every department (from molding and coremaking to engineering, quality inspection, and patternmaking, to name a few) instilled countless lessons. For example, this comprehensive exposure revealed that every person, on the shop floor or in the office, contributes to casting quality. We are all customers to each other, and our operational success is only as strong as the weakest link. 

Another important lesson: Global perspective matters. The foundry industry operates in a global marketplace where suppliers worldwide are simply trying to make a living, just like us. The misconception that overseas foundries are somehow inferior or attempting to “reverse engineer” parts is counterproductive and ignores historical reality—the first metalcastings weren’t made in the U.S. or Europe, and some global suppliers have been perfecting their craft longer than others.

Over the course of a long foundry career, Hoyson naturally saw patterns repeated—when you learn to recognize  them, you can drive real-world problem-solving. Consider this example: A casting supplier was producing 5-metric-ton center castings that consistently measured out of tolerance during dimensional inspection, and were thus relegated to scrap. Rather than diving into complex analysis, I asked to examine the coreboxes. As suspected, the corebox was assembled with loose pieces that weren’t marked for consistent placement—they were interchangeable. The solution was simple: Mark loose pieces as 1-to-1, 2-to-2, ensuring consistent assembly. When the supplier asked how I knew to look there, the answer was straightforward: “I made this same mistake when working on the shop floor.”

Avoiding Critical Pitfalls

Young engineers frequently make several costly mistakes when working with foundries:

1.    Bypassing the casting process and focusing solely on machining and final part function represents a significant oversight. Taking care of casting fundamentals first often resolves issues that would otherwise surface during machining operations. Dr. Kannan notes, if you take care of the small things first, many times this will impact the final product when it goes to machining.”

2.    Over-specifying requirements creates unnecessary constraints. Stipulating both casting chemistry and mechanical properties simultaneously is like telling someone to make you a special dinner but only allowing specific ingredients while demanding it taste exactly as you want. The critical question becomes: What’s more important—meeting mechanical requirements or achieving specific chemical composition? Focus on end properties.

3.    Incomplete hardness specifications plague many projects. Engineers often specify Brinell hardness numbers (BHN) without designating where on the casting to measure. This ambiguity guarantees that somewhere on any casting, you can find whatever hardness the customer requests. Always specify exactly where hardness should be measured on the actual casting, not just the test coupon.

4) Skipping kick-off meetings for new parts or suppliers creates communication gaps that prove expensive later. Bring together the foundry, customer engineering, procurement, quality, pattern design, and machining teams to ensure everyone understands requirements and expectations from the start.

The foundational advice remains: Detail, detail, detail. Just like a carpenter measures twice and cuts once. Thoroughly review what’s being asked—material type and grade, mechanical requirements, non-destructive testing (NDT) specifications, pattern design, delivery dates, and packaging requirements. This will save a lot of time and cost and will prevent delay down the road as the project progresses.

Building Effective Teams: 
The Human Element

Young engineer, get your hands dirty! You can’t run a foundry from the office alone. Go out on the floor, meet the workers, ask about their day, understand problems they’re facing, and seek their suggestions for improving parts or casting processes. They understand the various casting processes better than anyone because they work with them daily.

It’s important to explain the why behind foundry decisions. A number of years ago, during a business slump, foundry engineers developed an alternative pattern design that saved the customer money while keeping work in the shop. The casting was difficult to make due to the pattern design, and workers complained. As the customer’s foundry representative, Hoyson explained the reasoning: how the company was trying to keep everyone working by developing an alternate pattern for a large casting at a lower cost—not to just make things more difficult out on the floor. The tension disappeared once workers understood the purpose behind the challenging work.

Remember, leadership isn’t about getting to call the shots. One foundry owner consistently demonstrated servant leadership by walking through the shop each morning, talking with workers about how things were going. On one occasion, when Hoyson was struggling with a massive 10- to 12-ton HPM center core, the owner stopped to offer help. His words remain memorable after 44 years: “My job here at the foundry is to do the best I can so that you can do your job.”

This principle extends globally. Dr. K. emphasizes the importance of cultural sensitivity when working internationally: In certain cultures, it is rude to point out mistakes people have made—it is equivalent to shaming them in public. Any corrections should come across as suggestions and requests for better understanding. Success requires taking time to understand the culture of the organization or country you’re visiting by attending meetings and asking for guidance from various team members.

Essential Skills for Career Advancement

Technical competence in the foundry industry spans two primary categories: design/drawing work and shop floor operations.

1.    For shop floor engineers: Master sand and sand control—this skill alone can make or break profits. Conduct regular sand testing at least twice a week with tensile testing done daily and all other sand lab testing as set by the foundry to be done by the same person using the same method for repeatability. A dedicated sand engineer is worth their weight in gold.

2.    Understanding casting defect analysis is equally critical—remember that not all casting defects are porosity. You must know what the defect is first, then work backward to correct the problem and prevent recurrence. Heat treatment fundamentals and moldwash application round out essential shop floor competencies.

3.    For design engineers: Prioritize geometric dimensioning and tolerancing (GD&T) training, gating and risering design, and NDT fundamentals. While you don’t need Level II or III certification, understanding ultrasonic testing (UT) and magnetic particle testing (MT) provides significant benefits. Add 3D modeling capabilities to complete the skill set.

4.    On the subject of simulation software integration, Dr. K. recommends checking with your foundry to see what simulation software they use. Start looking at simulations already completed. Ask to attend a training session. This is an important skill for any foundry person. The key is integrating these digital tools with practical foundry experience.

5.    You need a metallurgical foundation—metallurgy knowledge forms the foundation of good foundry practice. If you are not already a metallurgist, enroll in metallurgy courses offered at local universities, AFS, or ASM International. This knowledge will be essential for problem-solving, project work, and upper management roles.

6.    Embrace safety protocols. Get involved with your company’s safety committee and develop weekly walkarounds. A fresh set of eyes in different departments helps identify potential problems that regular workers might have become accustomed to working around. Follow the foundry equivalent of “no shoes, no shirt, no service”—no hard hat, safety glasses, ear plugs, or steel-toe shoes means no entry. At the company where Hoyson works—like many other foundries—safety takes precedence over everything. You can make these castings every day, but each person is irreplaceable.

Designing for Success: Balancing Competing Priorities

Start with the “end game” in mind. What does the final customer require and why? This fundamental question drives all subsequent decisions. Have a thorough understanding of what the end customer needs, as this impacts foundry processes downstream.

1.    Challenge quality requirements with supporting data. Do we need specific processes performed, and what data supports these requirements? Understanding cost impact on both purchaser and foundry is essential. Quality comes with a price—foundries can meet almost any requirement, but financial impact, risk, and delivery implications must be understood. Be transparent with the customer.

2.    Pattern work efficiency varies dramatically based on application. Heavy-section iron and steel castings weighing over 100 metric tons can be produced using simple sweeps and core boxes depending on the complexity of the part and the skillset of the workforce. For example, one supplier’s sweep and core box cost represented between 1%– 5% of total casting cost, compared to a full wooden pattern from another supplier that ranged between 15–20% of total cost for a one-time casting. 

Styrofoam patterns offer another cost-effective solution for large, infrequent castings. They produce roughly the same casting quality as expensive wooden patterns at lower cost and faster turnaround time. Modern foundries are also embracing 3D printing technology, though success depends more on quality 3D or STP files than traditional pattern design skills. 

3.    To optimize sand consumption, work smarter, not harder. Look for ways to use less sand while maintaining casting quality. Some global and domestic suppliers have innovated the use of round, hollow, metal balls (about the size of a bowling ball with holes like oversized wiffle balls) to be used during molding and coremaking. Each ball saved about 1 cu. ft. of sand and resin, and these are added away from the metal wall interface during molding and coremaking. For larger castings, special blocking or wedges can replace backing sand.

4.    While considering surface finish, you must understand that quality requirements have to match functional needs. Hoyson once witnessed two identical crusher castings side by side—ours looked like a brand-new shiny penny while our competitor’s had unacceptable surface finish to our visual standards. Both had identical functionality and mechanical properties, but the other casting customer didn’t require the higher finish, which made a big difference on quality requirements and cost.

Global Foundry Partnerships

International foundry relationships require additional considerations beyond domestic partnerships. Remember that ASTM and other American standards aren’t the only standards globally—build an electronic library of international standards and develop comparison analysis capabilities when necessary.

Language and translation create ongoing challenges during international supplier development. Extra communication—what we call “hand holding”—ensures customer and foundry have clear understanding of requirements and expectations. However, the fundamental approach remains consistent: Treat foundry workers and management globally the same way you would treat domestic suppliers and how you would want to be treated. We are all foundry professionals.

The Path Forward: Sustainability and Innovation

Sustainability is an emerging field with significant opportunities for young engineers. Both authors have witnessed successful reclamation projects for sand, scrap metal, slag, and aluminum dross across various foundries globally. Kannan encourages young engineers to enroll in courses and be a part of your organization’s efforts. Volunteer for any projects and learn as you work.
Similarly, Industry 4.0 technologies require metallurgical expertise as foundation. Take time to learn and participate in projects involving computer control processes, IoT devices, and AI applications. These technologies enhance—rather than replace—fundamental foundry knowledge.

Continuous Learning: 
The Non-Negotiable

Stay current by joining AFS chapters, reading industry articles, taking additional training, participating in panel discussions, and sharing thoughts and questions. Learning never stops in this industry. As one veteran has noted: “You are never too old to learn.”
The foundry industry thrives on experience, mentorship, and willingness to bridge theoretical knowledge with practical application. Success comes from respecting both the science and art of metalcasting while maintaining focus on what truly matters: delivering quality castings that meet customer needs efficiently and safely.

The next generation of foundry engineers has unprecedented tools at their disposal: simulation software, advanced materials, automated systems, and global connectivity. 

However, the fundamental principles remain unchanged: Understand your process, respect your people, focus on customer requirements, and never stop learning from those who’ve walked this path before you.

Remember, a service-oriented mindset, combined with technical competence and global perspective, positions you—a young engineer—not just for personal success but for advancing the entire metalcasting industry into its next chapter of innovation and growth.

The bridge between classroom theory and shop-floor reality isn’t built overnight—it requires mentorship, experience, and the humility to learn from both successes and mistakes. But for those willing to get their hands dirty and embrace the challenge, the foundry industry offers a career path rich with problem-solving opportunities, global impact, and the satisfaction of transforming raw materials into the components that build—and now sustain—our world.