Byline: Brian Lewis, Executive Director, Foundry Educational Foundation
Brian Lewis is the Executive Director of the Foundry Educational Foundation, an organization established in 1947 that strengthens the metalcasting industry by fostering partnerships between educational institutions and industry to ensure today’s students are tomorrow’s leaders.
I am pleased to share my thoughts with Waupaca Foundry customers, suppliers and associates to mark yet another achievement for our industry. For the first time, the Foundry Educational Foundation (FEF) has established an endowed faculty chair at one of its certified schools! The faculty chair was created in the Industrial Studies Metals Processing Technology program at the University of Wisconsin—Platteville. This important milestone was reached thanks to a lead gift from Waupaca Foundry, and several major contributors including Badger Mining, Neenah Foundry, Kohler Foundation, American Colloid Company, Magma, and Aarowcast, along with other companies, alumni, and friends of FEF. The endowment, aligning with FEF’s mission, will ensure the university continues to educate the next generation of foundry leaders. The UW-Platteville foundry program is under the leadership of FEF Key professor, Dr. Kyle Metzloff. Earnings from the endowment will underwrite his salary to ensure this top tier program continues to produce outstanding technical graduates for the metalcasting industry.
As an organization, FEF provides support for 20 certified universities with foundry programs through donations from partner companies and individuals. We have awarded more than $1.5 million in scholarships, and FEF supported foundry programs have placed over 400 graduates in metalcasting jobs in the last five years. A number of those graduates are employed at Waupaca Foundry and other foundries throughout the Midwest—many are alumni of the foundry program at UW-Platteville.
This endowment is a precedent for FEF and would not have been possible without support from Waupaca Foundry, our campaign cabinet, and our many generous corporate and individual donors. Our goal was to create a sustainable model to ensure those passionate teachers—the FEF Key Professors—stay at reputable universities. These educators are critical to igniting passion for metalcasting in talented and highly qualified students.
With the support from Waupaca, our organization chose UW-Platteville and Dr. Metzloff for this groundbreaking endowment because his leadership has created excitement and curiosity in students. This is something that Waupaca has experienced for many years in hiring UW-Platteville graduates. Dr. Metzloff’s program focuses on hands-on experience in the foundry lab and real-world exposure to working foundries along with a broad-based curriculum. These aspects encourage graduates to realize the potential of a career in metalcasting. Manufacturing in the United States is graying and we all know it’s essential to our partners to continue to attract the best and brightest into technical curriculums like the UW-Platteville program. Beyond that, the metalcasting industry needs people who have a passion and interest for foundry work—young people who look at manufacturing and get excited about the durable products made.
Several graduates of the program credit Dr. Metzloff’s passion and enthusiasm for hooking them on foundry work. Kelsey Schwantes is a lead process engineer for Waupaca Foundry and said the program gave her unlimited opportunities. “It’s not only how Kyle teaches, but his industry connections. It’s not just classroom instruction, it’s the tours and the lab work that drive everything.”
Ryan Hansch is an assistant tooling manager at Waupaca Foundry and credits the real-world experience he got as a student with his success. “Platteville is regarded as one of the better schools in the nation for its foundry program because a lot of what happens in the real world actually does happen in that lab.”
Steve Nygaard is a tooling engineer who got early exposure to working foundries in Dr. Metzloff’s program. “We got exposed to industry professionals while we were still students so we got used to talking to everyone from the guy who runs the molding machine to the guy who owns the foundry. It got me comfortable talking to people who I would eventually be asking for a job.”
Graduates from the Platteville program are at some of the nation’s largest manufacturers, like Mary Cartier who is a continuous improvement coordinator for Kohler Company. She said the foundry program opened her eyes to a career in manufacturing. “There are a lot of misconceptions about jobs in metalcasting. Millennials don’t want to sit in a cubicle all day long and in my job I’m only at my desk 25% of the day. I’m always doing something different, talking to people, and using my creative skills.”
Dr. Metzloff credits hands-on lab work with generating great enthusiasm in the students, but he’s keenly aware of the program costs. The space and operational costs required for a foundry lab are an investment for any university, but updated facilities and quality teachers are critical to sustaining successful metalcasting programs. In Dr. Metzloff’s words, he’s grateful for the investment in his program. “This shows that Waupaca Foundry and Hitachi Metals have confidence in our program to supply their needs into the future. Their foresight is amazing and allows Platteville to build a program that will continue for generations, well beyond my time.”
Since 1947, FEF’s goal has been consistent in its mission to contribute to the success of the metalcasting industry starting with investing in our young people. With inspirational teachers like Dr. Metzloff and collaborative partners like Waupaca Foundry, we will be able to continue to steer our best young technical minds into the foundry field.
At times all it takes is determination and one person to change the world and that’s just what Waupaca Foundry employee Dave Hintz is doing—one deer hide at a time.
Dave started a unique partnership called Hides 4 Heroes to support veterans through the Wounded Warriors in Action Foundation. During the Wisconsin bow and gun deer seasons, Hintz sets up hide collection locations throughout the Northeastern, Central and Northern Wisconsin region. He volunteers his time to collect and cure the hides, then sells them to a broker. The funds raised are donated to Camp Hackett near Phillips, Wisconsin where veterans participate in outdoor sporting activities designed to help heal mental and physical wounds from active duty.
Since 2012, he has donated $14,000 through his Hides 4 Heroes project thanks to a partnership with Waupaca Foundry and regional hunters. In 2015, Hintz collected 780 deer hides from harvests throughout Wisconsin and this year, he hopes to break records.
Hintz was inspired to support veterans when he met Matt Tennessen while hunting in northern Wisconsin. Tennessen was wounded in 2009 from an IED blast while serving in Afghanistan and his stories of recovery impressed Hintz who decided to get involved.
“I wanted to give back,” Hintz said. “When Matt told me his story and how the Wounded Warriors in Action Foundation helped veterans, I knew this was something I could do. Most guys throw their hides away, and I knew they could be useful.” A life-long hunter, Hintz had a side business of butchering deer during the hunting season and knew there was a market for cured hides. Last year, many of the hides he collected ended up in Italy and were used to make boots and purses.
Hintz contacted his employer, Waupaca Foundry, to help with the project. The foundry donated collection boxes and the nearly 2,000 pounds of salt Hintz uses to cure the hides each season. Hintz has worked at Waupaca Foundry for 27 years and said the company’s support is gratifying.
Waupaca Foundry has a history of supporting veteran’s causes and in 2015 was awarded the Patriot Award for employer support of the National Guard or Reserve. About 11% of the foundry’s workforce are veterans and many of the skills learned on active duty directly apply on the job, according to Joey Leonard, executive vice president of human resources.
“Veterans put direct experience in leadership, responsibility, teamwork and many other attributes to work for us daily and we are honored to support causes that support veterans,” he said.
Hintz will be collecting deer hides through January 13, 2017 and hides may be dropped off at these participating locations:
Waupaca Foundry, 406 N. Division St., Waupaca
Waupaca Foundry, 1955 Brunner Drive, Waupaca
Chain BP, King
JR's Sports Shop, Iola
Depo Street Station, Iola
Scandy "C" Store, Scandinavia
Sand Burr Corners, Ogdensburg
Waupaca Truck Stop, Waupaca
The Cenex, Weyauwega
Sun Set BP, Weyauwega
Machow Sports, Wild Rose
Badger Sports Center, Phillips
Elk River Rods, Phillips
Corner Connection Bar, Phillips
Manufacturing Day℠ is a celebration of modern manufacturing meant to inspire the next generation of manufacturers. Although Manufacturing Day officially occurs on the first Friday in October - this year is Oct 7, 2016 - any day can be a Manufacturing Day.
MFG DAY addresses common misperceptions about manufacturing by giving manufacturers an opportunity to open their doors and show, in a coordinated effort, what manufacturing is - and what it isn’t. By working together during and after MFG DAY, manufacturers will begin to address the skilled labor shortage they face, connect with future generations, take charge of the public image of manufacturing, and ensure the ongoing prosperity of the whole industry.
Waupaca Foundry Manufacturing Day 2016. Each of our locations will be hosting an event. Activities may include a tour of our state-of-the-art facilities, Foundry in a box simulation and mini cupola demonstration. Our experts will guide you through the process of making your own tabletop casting using melted tin. We will also be happy to answer any questions about our iron castings, our foundry or the industry in general. Check our listings below (October 6 and 7) for event details.
Manufacturing Day was instituted, in North America, to inspire the next generation of manufacturers. By opening our manufacturing doors to the community, Waupaca Foundry and our peers hope to dispel common misconceptions and attract a skilled workforce. Our aim; to make your experience as educational, interesting and personalized as possible.
Date: October 6, 2016 9:00am - 3:00pm
Location: 805 Ogden St, Marinette, WI 54143
Join us for FOUNDRY IN A BOX, a one-of-a-kind opportunity to learn how the foundry operates. You’ll get to create and keep a casting. What better way to learn how our foundry operates?
*Note: Must be 16 years of age to tour the facility. Long pants and closed-toed shoes required.
Date: October 6, 2016 4:00pm - 6:00pm
Location: 1500 Heartland Ave, Effingham, IL 62401
Don’t miss the opportunity to see automated machining and manufacturing at its best. Tour our sophisticated facility and view our highly technical processes that display innovations in robotics and automation.
*Note: Must be 16 years of age to tour the facility. Long pants and closed-toed shoes required.
Date: October 7, 2016 9:00am - 2:00pm
Location: 1955 Brunner Dr., Waupaca, WI 54981
Invited students join us for FOUNDRY IN A BOX, a one-of-a-kind opportunity to create and keep a casting. What better way to learn how our foundry operates? From molding and pouring to shakeout and cleaning, we will show you exactly how it’s done. In addition, our mini cupola will be set up with viewing and demonstrations of high temperature melting and pouring of actual iron.
Date: October 7, 2016 10:00am - 2:00pm
Location: 134 Waupaca Drive, Etowah, TN 37331
Join us for facility tours and FOUNDRY IN A BOX, a one-of-a-kind opportunity to create and keep a casting. What better way to learn how our foundry operates? From molding and pouring to shakeout and cleaning, we will show you exactly how it’s done.
Since the Foundry in a Box program started, Waupaca Foundry has reached 24 K-12 school districts across the U.S. and more than 2,000 students have been exposed to foundry processes. To request the Foundry in a Box program for your school or STEM event, please contact Waupaca Foundry’s manager of training and development.
Waupaca Foundry, a Hitachi Metals Group company, is a leading supplier of iron castings to the automotive, commercial vehicle, agriculture, construction, rail, and industrial markets. Our unwavering commitment to providing value and dependability to the millions who use metal castings everyday has helped make customers for life. Sophisticated technology, proven green processes and a highly-trained workforce enable us to exceed your expectations of quality and service. Our staff takes great pride in what they do and we encourage them to advance their skills and career through continuing education and an attractive compensation package.
Learn more about our Manufacturing Day events at mfgday.com!
Waupaca Foundry and Hitachi Metals will join Volkswagen, other OEM’s and 750 Tier suppliers at IZB 2016 October 18 – 20. IZB 2016 is being held at the AutoBook International Pavilion located next to the global Volkswagen Headquarters in Wolfsburg, Germany. Stop by and talk to Waupaca Foundry’s Carsten Behrensmeier and James Newsome at IZB 2016 Booth 4203 in Hall 4 to discuss your next project.
Millions of people rely on Waupaca Foundry castings every day. Our light vehicle automotive casting components are of the highest quality. Source iron castings from Waupaca Foundry to give your automotive parts consistent quality—achieving your lightweighting objectives, improving machinablity, and reducing total manufacturing costs. Waupaca Foundry combines casting design, material solutions, and computer simulation to produce gray iron and ductile iron castings that have the quality, consistency and performance that our customers have come to trust.
In addition to manufacturing iron castings, we provide value added services to streamline the assembly and manufacture of your passenger car and light truck components and systems. This includes casting design collaboration and VA/VE support, machining and assembly, heat treating, and paint services to achieve your lightweighting and cost reduction objectives. Automobile industry OEM’s and Tier 1 suppliers rely on our foundry expertise, innovative solutions and cost-effective iron casting supply services to gain a competitive edge.
With nine foundry and machining/assembly locations in the United States, more than a million tons of capacity, and key account managers worldwide, you can count on our consistent, high-quality iron casting components.
The IZB was first hosted in 2001 as a Volkswagen in-house trade fair with 128 exhibitors from six nations, which attracted 13,500 visitors. It has since established itself as a showcase event for the international automotive supplier industry. In 2014, the organizers recorded a total of 51,000 visitors to the fair including 821 exhibitors from 29 nations taking advantage of the trade fair to showcase their products and innovations.
The IZB represents the entire automotive value chain. The key areas of the IZB are:
The International Suppliers Fair (IZB) is aimed at all automotive industry suppliers and has a prominent reputation in international professional circles. The high-quality exhibitors and large number of key decision-makers and trade visitors that attend the IZB make it an important communication and business platform for the industry.Contact Us or Request a Quote Today! And we look forward seeing you at IZB 2016.
InnoTrans, the world’s leading transport technology fair, is set to attract more than 135,000 visitors from 55 countries to Berlin in September 2016. Waupaca Foundry, Inc. is on track to showcase our portfolio of gray iron and ductile iron castings for use by passenger and freight car component manufacturers. Join or follow us in Berlin as we discuss our advanced manufacturing technology, consistent high quality, and continuous cost conscience methodology with OEM’s and Tier 1 Suppliers to the rail industry.
The rail industry relies on trusted suppliers like Waupaca Foundry to keep its customers’ rail cars and locomotive engines in service, making money. Our high quality iron castings meet demanding specifications ensuring durability, extended wear and superior performance in the field. And through casting design collaboration and material solutions Waupaca Foundry can help you meet your light-weighting and cost reduction objectives.
Waupaca Foundry recognizes that our rail customers are committed to help railroads all over the world haul heavier loads over greater distances with improved reliability and performance. So we are also committed to advance the rail industry with iron casting component innovations that improve productivity, safety and efficiency. Our flexibility is a key benefit when projects come in with short notice or demanding turn-around times. Our innovative gray iron and ductile iron casting solutions help these OEM’s and Tier 1 suppliers remain a step above their competitors.
We welcome the challenges your complex designs and specifications offer. These challenges give us the opportunity to demonstrate our expertise encouraging manufacturers worldwide to source their railcar and locomotive engine components from Waupaca Foundry. Our castings improve performance and service life of your systems and components. Stop by and talk to Waupaca Foundry’s Carsten Behrensmeier at InnoTrans 2016 booth 212 in Hall 10.1 to discuss your iron casting supply needs.
At Waupaca Foundry we set the benchmark for quality and reliability as an iron casting manufacturer. As a trusted supplier to passenger, freight, tank, oil and coal car manufacturers, we supply iron castings for:
In addition to manufacturing iron castings, we provide many value added services to streamline the assembly and manufacture of your rail components and systems. This includes casting design collaboration and VA/VE support, machining and assembly, heat treating, and paint services to reduce the time and cost to market. Rail industry manufacturers rely on our foundry expertise, innovative solutions and cost-effective services to gain a competitive edge.
With nine foundry and machining/assembly locations in the United States, 1.5 million tons of capacity, and key account managers worldwide, you can count on our consistent, high quality iron casting components.
When a young person says “I want to be a firefighter when I grow up,” there’s a clear visual image of that career. But when a young person is told “you could have a career as a quality engineer,” there’s no reference point. But Waupaca Foundry is working to change the image of tomorrow’s industrial careers.
According to the Manufacturing Institute, American manufacturing will need to fill 3.5 million skilled jobs over the next decade. The institutes’ 2015 Skills Gap Report shows that almost 2 million of these jobs will go unfilled because manufacturers cannot find qualified applicants.
At Waupaca Foundry, teams of employees are sparking interest in STEM careers with an innovative program.
In a plant setting, molten iron is poured into sand molds (about the size of a chest freezer) to make the parts found in cars, tractors, and even fire hydrants. At the schools, it all happens on a table top in a program called “Foundry in a Box.”
The team literally puts a mini-foundry in a metal box along with a small electric furnace that melts tin to about 500-degrees. Molds to hold the liquid tin are made from a mixture of sand and vegetable oil. The process is very similar to building a sand castle where sand is packed to create impressions in the mold.
Under the supervision of trained foundry men and women, students don safety equipment, manufacture the sand molds, help pour liquid tin into molds, and sand off rough edges to make a variety of objects including keys, paper weights and horseshoes. During the demonstration, Waupaca Foundry employees talk about their careers and educate the students on how the tasks they are doing relate to jobs in the foundry—jobs in engineering, machining, electrical work and metallurgy.
“It’s about educating students on what we do at Waupaca Foundry and making sure we have good workers in the future,” said Rusty Brandt, tooling and layout manager at Waupaca Foundry in Waupaca, Wisconsin.
Waupaca Foundry has been bringing this program to Wisconsin schools for several years and teams from each foundry have demonstrations planned through the 2016 school year. Each visit reaches anywhere from 20-300 students at a time.
Many of the schools have no formalized programs or clubs focused on STEM technology or jobs and this demonstration opens students’ minds to manufacturing careers. “Many tend to stereotype foundry work as the place for those who have chosen not to pursue higher education, while this program demonstrates just the opposite! It is the new foundry career!” said Amy Anaya from Iola-Scandinavia Elementary School in Wisconsin.
Waupaca Foundry’s “Foundry in a Box” earned the 2016 Manufacturing Innovation Award from the Northeast Wisconsin Manufacturing Alliance. The Alliance recognized manufacturers such as Kohler Company, Georgia Pacific, Vollrath and Waupaca Foundry for programs that show students how careers in engineering, production, quality, metallurgy, maintenance are exciting options for their future.
“There’s a science and an art to metalcasting and we want our youth to see the possibilities,” said Amie Borchardt, a lead process engineer at Waupaca Foundry.
Borchardt was honored by the Northeast Wisconsin Manufacturing Alliance as a 2016 All Star Mentor for her work in promoting STEM careers, specifically for women. She acknowledges there are still barriers to attracting more women to manufacturing, so girls need to know the career options available to them.
“We’ve got a really good team,” Borchardt said. “We’ve got a lot of up-and-comers who have taken opportunities to go to school and are replacing our retiring work force. To me, that’s exciting.”
Team members who champion Waupaca’s Foundry In a Box hold a variety of jobs at the company from foundry production employees to engineers and quality managers. For company leaders and employees, the demonstrations help ensure there is a next generation of foundry men and women.
Waupaca Foundry CEO Mike Nikolai began his career as a metallurgical engineer working at all three plants in Waupaca. He holds a masters degree from the University of Wisconsin—Madison and an M.B.A. from the University of Louisville which have taught him the value of STEM education.
“Our industry continues to change due to automation, robotics and continual innovation,” Nikolai said. “In the future, students who pursue STEM related careers will find entry level positions pay 25-30% higher compared to non-STEM jobs.”
Since the Foundry in a Box program started, Waupaca Foundry has reached 24 K-12 school districts across the U.S. and more than 2,000 students have been exposed to foundry processes. To request the Foundry In a Box program for your school or STEM event, please contact Waupaca Foundry’s manager of training and development.
The Department of Commerce and International Trade Commission suspect driveline components exported from China and Canada to the US are sold at prices below fair market value or are being subsidized by a foreign “authority”. However, a new anti-dumping or countervailing duty rule could change that. Preliminary findings of investigations by the Department of Commerce into subsidies and dumping allegations indicate that duties could soon be imposed on iron castings from these two countries.
“Dumping occurs” when a foreign company sells a product in the United States at less than its fair value. The anti-dumping law provides US businesses and workers with an internationally-accepted mechanism to seek relief from the market distortion caused by such imports. If final investigations by the Department of Commerce and U.S. International Trade Commission (ITC) determine the allegations on the Chinese and Canadian driveline components to be true, an anti-dumping rule with strict duties is likely to come into effect in the near future.
On April 11, 2016, the Department of Commerce International Trade Administration (ITC) published preliminary determinations that countervailable subsidies are being provided to producers and exporter of Driveline Components from the People’s Republic of China. The preliminary determination is currently in its comment period. The notice sets forth Countervailing duties on driveline components from several manufactures in the People’s Republic of China ranging from 2.68% to 166.77% and a duty of 15.51% on all producers not specifically named in the notice. The ITC also announced their intention of aligning the Countervailing Duties Final Determination with the Final determination of the companion Anti-dumping investigation. The final Countervailing duty determination will be announced with the final anti-dumping determination, currently scheduled for December 2016.
On June 1, 2016, the Department of Commerce announced its affirmative preliminary determinations in the anti-dumping duty investigations of imports of certain iron mechanical transfer drive components from Canada and the People’s Republic of China (PRC). Several categories of driveline components made of grey or ductile iron were investigated, including:
The Department of Commerce is scheduled to announce its final determinations on or about October 21, 2016 while ITC will make its final determinations in December 2016. Affirmation decisions by both will lead to anti-dumping orders being issued.
If your manufacturing business relies on finished or unfinished iron mechanical transfer drive components from China and Canada, it might be worth your while to explore a US based foundry as an alternative. Being proactive may prevent any unnecessary operational delays or unexpected costs that occur if the tariffs are imposed.
For US-made, quality driveline components that deliver performance and value, consider Waupaca Foundry. OEMs and Tier I manufacturers across the United States, Mexico and Europe rely on our casting design expertise and product development collaboration for high-performing, wear resistant and consistent high-quality iron castings. In addition to improving machine cycle time and machine tool life, we are able to improve your total manufacturing cost. As a trusted iron casting component supplier for the agriculture, construction, and industrial markets, Waupaca Foundry offers a full line of components for off-highway applications.
With nine foundry and machining/assembly locations in the United States, 1.5 million tons of capacity, and key account managers worldwide, you can count on our consistent, high quality iron casting components.
At its 15th annual awards banquet, Perry County Chamber of Commerce awarded Waupaca Foundry in Tell City, Indiana the 2016 Large Business of the Year. The gray iron and ductile iron foundry was recognized for its business practices and contributions to the community. The Chamber cited Waupaca Foundry’s commitment to the community, including its financial and in-kind support to public and technical schools, as well as countless local charities, events and fundraisers benefiting the enrichment of Perry County residents and businesses alike. Recent, major initiatives include civic collaboration to establish the County’s second helipad and Perry Childcare.
In the nomination form Mary Roberson, superintendent for Perry Central Community School said, “Waupaca Foundry has changed Perry County for the better in many ways over the past 20 years. As a community we are fortunate for their generosity, but equally important is Waupaca’s attitude of common sense solutions and ways to solve local challenges. It is particularly fitting that Waupaca Foundry is honored during this, their 20th anniversary year.
Pictured here accepting the award (left to right): Rick Sutton, Roxanna Stein, Shelby Applegate, Bruce Tesch, Gary Greubel, Cody Dawson, Ross Hendershot, Joey Leonard, Brian Hammack, and Jeremy Backer.
Waupaca Foundry is humbled to be named Large Business of the Year. Our goal is to be the industry leader in iron castings, but it’s also our passion to give back to the communities in which we operate. Our achievements depend on collaboration between civic leaders, businesses and residents alike.
Waupaca Foundry, headquartered in Waupaca, Wis., has operated in Tell City, Indiana since 1997. To meet customer growth and demand, construction of the Tell City ductile and gray iron foundry began in the fall of 1995. Today, Waupaca Foundry employs 4,400 in the U.S. The Tell City foundry operation employs 960 full-time workers, more than twice than what was projected when operations began in 1996. Today, the average annual payroll exceeds $65 million in Perry County and surrounding communities.
Waupaca Foundry’s Joey Leonard assisted the American Foundry Society (AFS) Pennsylvania contingent by awarding the Metalcasting Industry Eagle Award to United States Senator, Pat Toomey (R-PA). This award is presented annually to lawmakers who support policies in Congress that enhance the ability of U.S. foundries to create jobs and innovate, as well as those who fight back against burdensome and costly regulations that hinder metalcasting industry growth. The annual event hosted by AFS was held at its Government Affairs Conference in Washington, D.C. on May 18, 2016.
Senator Toomey’s district is located in eastern Pennsylvania. The district stretches from the suburbs east of Harrisburg to communities east of Allentown and the New Jersey border. Eastern Pennsylvania has a rich manufacturing history and is home to over 15 Metalcasting facilities, including our ductile iron foundry in Lawrenceville, PA and machining and assembly facility in Wellsboro, PA..
Joey Leonard with the AFS Pennsylvania Foundry Association, present an Eagle Award to U.S. Senator Pat Toomey on May 18, 2016. Pictured (left to right): executive vice president and secretary of Pennsylvania Foundry Association Chris Moyer, Alan Brink, president of Spring City Electrical Manufacturing Co. Inc. , U.S. Senator Pat Toomey, vice president of T.B. Woods Corporation Inc. Bill Juergens, director of technical operations with PRL Inc. Greg Raudenbush, and executive vice president of human resources Joey Leonard Waupaca Foundry Inc.
Senator Toomey has been a strong ally and supporter of the foundry industry. Primarily Toomey has assisted the industry by fighting for an increase of tax relief and decrease of regulations so both Metalcasting industries and other manufactures can thrive.
The American Foundry Society is a not-for-profit organization formed in 1896. With its headquarters in Schaumburg, Ill., AFS provides members and consumers with information and services to promote and strengthen the metalcasting industry.
One of Waupaca Foundry’s most innovative programs is hitting the road in the Etowah, Tenn. city school system. Team members from Waupaca Foundry Etowah brought the hands-on “Foundry in a Box” program to the school system’s STEM Fair in April and had more than 100 students and parents in attendance.
Benjamin Webb (left) learns about the goings on at Waupaca Foundry at the industry's booth Thursday evening at the Etowah City School STEM Fair. Numerous booths were set up throughout the school for the fair with each one representing the four STEM areas – Science, Technology, Engineering and Math. Photo credit: The Daily Post Athenian
Foundry in a Box is a customized program created by Waupaca Foundry that helps students understand the importance of science, engineering, technology and mathematics in today's world. Team members expose the students to STEM careers available right in their own communities.
At Waupaca Foundry, hundreds of pounds of (ductile/gray) iron is poured into sand molds (about the size of a chest freezer) to make the parts that keep cars, tractors, and even fire hydrants in working order. At the schools, it all happens on a tabletop.
The team literally puts the foundry in a plastic box along with a small electric heater that melts tin to about 500-degrees. Molds to hold the liquid metal are made from a mixture of sand and oil. The process is very similar to building a sand castle where sand is packed to create impressions in the mold. Under the supervision of trained foundry men and women, students don safety equipment, manufacture the sand molds, help pour liquid tin into molds, and use files to sand off rough edges to make a variety of objects including keys, pins and key chains. During the demonstration, Waupaca Foundry employees explain that engineers, machinists and metallurgists helped create Foundry in a Box and educate the students on how the tasks they are doing relate to jobs in the foundry.
Etowah team members say the program was so successful, they ran out of sand!
“During the STEM Fair, all the other booths came down to our end of the building to see what the large crowd was doing,” said Quality Manager, Diana Elrod.
“As we poured the metal into the molds and we let the kids finish the products, the entire time we were discussing the properties of sand and mental. They were asking intelligent questions and I guarantee before that day they never thought of those concepts,” Elrod said.
Elrod says Waupaca Foundry Etowah has made the presentation several times to classrooms and will be participating in a STEAM camp this summer to give students a better understanding of the engineering and foundry jobs available right in their own backyards.
Our goal is to help you. Period. Our metal casting experts will keep you current in the world of gray, ductile, compacted graphite, and austempered ductile iron castings by providing unique information and perspectives on raw materials and scrap metal trends, optimizing casting design, improving quality, and helping you reduce total manufacturing costs. We share stories and offer tips and hints.