In the Vital Metalcasting Industry, Reliable Foundry Partners are Key

The metalcasting industry is critical for producing durable, high-strength parts essential to the performance and safety of products, vehicles, equipment, and buildings. According to the American Foundry Society (AFS), highly engineered castings are used to produce 90% of all manufactured durable goods and nearly all manufacturing machinery. The industry drives technological innovation, economic growth and job creation, while also contributing to advancements in material science and recycling.

And while foundry ownership continues to consolidate, casting sales are on an upward trend due to an increasing demand across sectors including automotive, aerospace, construction, and energy. The AFS 2024 Metalcasting Forecast & Trends report projects casting sales will increase for the fourth straight year, this year at a rate of 5.3%. Industry revenue, which was estimated at $50.1 billion in 2023, is expected to grow at a rate of 4.6% per year from 2024 through 2028.

Foundries are meeting increasing demand with technological advancements. Innovations in design, metallurgy, and production are helping to improve the quality and efficiency of cast products, making them even more appealing for end users who desire minimal maintenance and long life cycles.

Original equipment manufacturers (OEMs) need strong, reliable foundry partners in this with the experience and capabilities required to step up to a challenge. The following are four ways to know if the foundry you are considering is right for you.

Ongoing Capital Investment

Investing in capital improvements is crucial for foundries to enhance productivity, comply with environmental regulations, and address labor challenges. Modernizing equipment with advanced machinery and automation boosts efficiency and product quality, reducing costs and waste.

Stainless Foundry & Engineering has undergone multiple phases of a capital improvement initiative with the goal of achieving operational excellence for both sand casting and investment casting. Multiple investments in 3D modeling and additive manufacturing help the SF&E engineering team provide custom and proven designs that will function properly the first time, saving customers time and money.

Our throughput improvement initiative streamlined the entire foundry facility by dropping the traditional batch mentality of production and moving to a single piece flow. Today our production lines prevent bottlenecks by design, are flexible to increase capacity or push a priority order through and are equipped with cross-trained employees to keep processes moving.

This year, SF&E has several capital investments planned that target improved safety, quality, and productivity. A recent addition was the installation of a Triplex Systems Combination Automatic and Manual Precision Cleaning Center. It’s a waterblast cabinet that contains the entire process of removing investment casting shells. Operators can produce a clean part before cut-off operations, eliminating the need for hand chisels and reducing the number of products that need to go to Kolene by 75%. It has already reduced costs and increased productivity significantly and has the added benefit of air quality improvement.

Superior Metallurgical Expertise

Metallurgical expertise is essential in a foundry for ensuring the quality and performance of metal castings. Metallurgists’ deep understanding of metal properties and behaviors enables precise material selection and process control, resulting in superior strength and durability of cast products. Their expertise in diagnosing and resolving defects minimizes production downtime and scrap rates, enhancing operational efficiency.

The metallurgist department at SF&E works with customers to discuss properties, selection, application, and specification of alloys. They are experienced in working with the over 250 alloys SF&E pours, and can tailor alloys to a specific application or requirement. SF&E metallurgists work with a part from start to finish – providing expertise and guidance to teams designing the pattern and rigging system, quality assurance testing, and machining.

Transparent Customer Communication

Transparent customer communication is a competitive edge for foundries as it builds trust, fosters strong relationships, and enhances collaboration. By openly sharing information about production processes, timelines, and potential issues, foundries demonstrate reliability and commitment to customer satisfaction. This transparency helps ensure more accurate fulfillment of customer requirements, leading to higher-quality outcomes and tailored solutions.

Since SF&E first opened its doors more than 75 years ago, it has differentiated itself from other foundries through its commitment to communication, responsiveness, and continuous improvement. These brand promises would be difficult to fulfill if we weren’t located within a day’s travel to every customer site. Our commitment to transparent communication is constantly improving through customer feedback and technology investments.

Transparent communication for SF&E customers means: a secure online portal for access to materials certifications and records updates, real-time status updates by phone or email, immediate change notifications, a proprietary expediting tool to elevate any order when needed, and regular internal communication so the entire SF&E team can work in synch.

Employee Growth and Development

Employees at a foundry can significantly develop their skills through hands-on experience with advanced machinery, continuous training programs, and exposure to innovative metalcasting techniques. Foundries often invest in professional development, offering workshops and courses that cover new technologies, safety protocols, and environmental regulations. This comprehensive learning environment not only enhances technical proficiency but also fosters problem-solving skills and adaptability, preparing employees for future advancements in the industry​.

Long-term and talented employees are key to the success story of SF&E. As SF&E has adapted to the changing needs of customers in a broad range of industries, operators have had the opportunity for additional training and certification. Instead of the traditional foundry job where an employee has one designated skillset, SF&E has found a direct connection between operational efficiency, production quality and employee morale and retainment when employees have multiple skillsets.

For example, the new waterblast mentioned earlier required some employees to be trained to use automated equipment instead of the hand chisel they were used to. Efficiency from the automation also freed up space in the cleaning rooms, allowing employees to work in different areas of the production floor.

Employees are the backbone of the SF&E business. It can take years to acquire the skills needed for most of the work completed in a foundry. When we invest in our employees’ career advancement, we are investing in our ability to grow right along with them.

Metalcasting is one of the most important sectors in the manufacturing economy. SF&E is a proud member of the American Foundry Society (AFS) and supporter of its mission to advance the success of the metalcasting industry through advocacy, education, and innovation.

If you are looking to learn more about SF&E industry expertise, how we can tailor our processes to meet your specifications, or are interested in what a reliable foundry partner can do for your business, contact us today.