The Non-Ferrous Founders' Society

THE NON-FERROUS FOUNDERS ’ SOC I ETY continue to need an influx of talented engineers, managers, and skilled tradespeople such as machinists, welders, and CNC programmers. NFFS has developed a targeted scholarship program to attract the nation’s best and brightest students to a career in non-ferrous metal casting. “I also believe that it is worth mentioning additive manufacturing as well. Many see additive manufacturing as a replacement technology that will supersede our nation’s need for non-ferrous foundries. This is simply not the case. Additive manufacturing has been adopted by many in our industry already, not to print metal components, but to use as part of the traditional foundry manufacturing process. Additive manufacturing helps foundries to make tooling, print complete sand molds and core assemblies, print ceramic investment casting shells and waxes, and provide rapid prototyping services. The efficiencies that additive manufacturing provides foundries are actually a net benefit to the foundry industry. Sure, there will always be winners and losers with any new technology, but for the foreseeable future additive manufacturing will not be cost effective for manufacturing large numbers of non-ferrous metal castings for use in the U.S. economy.” BVM: What is your view of the non-ferrous industry, as a whole, going forward? Weaver: “I believe the industry’s health is solid, long-term, but I think the mix of work that is done in non-ferrous foundries will change slightly. We’ve already seen the high-volume, low-complexity jobs move to locations with lower labor costs, such as China, and there’s a whole host of those countries coming in the future, in places like Africa. The high-volume, low-margin product types will continue to face pressure to migrate out of the country as economic demands dictate. Where the future is brightest for American non-ferrous foundries will be the low-to-medium volume, high-quality, highly- engineered cast components that are critical for advanced technologies and industries.” BVM: What are the most important points that you would like our readers to know about the NFFS? Weaver: “That’s a great question. I think that there are a couple of things that I hope a reader would take away from this article. One, foundries really have an undeserved bad reputation among the general public. The perception is that foundries are dark, dirty, low-tech, heavy industrial environments that are full of smoke and employee hazards and are poor environmental citizens. And nothing could be further from the truth. The truth is, if you actually visit almost any non-ferrous foundry in this country, you will see a professional work environment that is well lit, clean, and filled with advanced technology. Foundries routinely use computer simulation and computer controls as part of their planning and production processes, often times have advanced analytical instruments capable of measuring metal content within alloys out to 0.001%, and many have advanced non-destructive testing equipment right out on the foundry floor. Perhaps the more important point is that foundries are the original environmental champions. Foundries have been recycling metal for thousands of years, and long before recycling was ‘cool’. “The second point I would hope that a reader would take away is that the non-ferrous foundry industry is a vibrant and exciting place to work. For too long we have told our youth to be doctors, lawyers, or accountants, and have totally ignored the rich tapestry of opportunity available in the manufacturing trades. Non-ferrous foundries provide well-paying careers for tens of thousands of American families, and the opportunities in this industry have never been greater. Not only are there opportunities to start on the ground floor for entry level workers, there are literally hundreds of job openings right now for talented engineers, accountants, managers, and executives as well. My experience over the last 20-plus years in the industry is that once a young employee enters the non-ferrous metal casting industry, they tend to become life-long industry employees. Hopefully we are able to convince the next generation that working in manufacturing, and especially with cast metals, is a great career path and one that helps ensure America remains a manufacturing powerhouse in the global economy.”