The University of Tennessee at Knoxville (UTK) hosted an investment casting workshop in early March to introduce high school students to careers in metallurgy. 

The workshop was a part of the university’s partnership with METAL (Metallurgical Engineering Trades Apprenticeships & Learning).

Led by IACMI – the Composites Institute® with support from the Defense Department’s Innovation Capability and Modernization (ICAM) Office, METAL strengthens and diversifies the U.S. metal manufacturing workforce, focusing on casting, forging, and plate rolling. 

The investment casting workshop provided a hands-on introduction to metallurgy, allowing students to explore, experiment and consider a future in this essential field.

The Process of Investment Casting

Investment casting is a process that allows students to create metal objects from scratch.

The process begins with creating a pattern of the final object, which students can 3D print, injection mold, or carve by hand. The pattern is attached to a wax sprue, forming a network for molten metal. The pattern and sprue are then coated in a ceramic slurry. After hardening – which takes a few hours to several days depending on size – students place the ceramic-coated patterns in a high-temperature oven. 

Over about 13 hours, the temperature gradually rises to nearly 1400 degrees Fahrenheit, melting and burning away the wax to leave a precise mold. Typically a multi-day process, this process was condensed to fit the five-hour workshop, thanks to instructor preparation. 

Once the mold is ready, participants heat tin until it becomes liquid and pour it into the ceramic mold. METAL workshops use tin because of its low melting point and relative safety in a student learning environment. After cooling, the ceramic shell is dissolved, revealing the metal casting. Students refine their pieces by cutting excess material, filing edges and smoothing surfaces. 

“They get to leave with something that they’ve created with their own two hands,” said Amy Wheelock, research assistant at the University of Tennessee Tickle College of Engineering’s Fibers and Composites Manufacturing Facility.  “Right now, we’re doing everything from rings to keychains.”  

The Importance of Hands-On Manufacturing Education

Manufacturing plays a crucial role in the global economy and workforce, contributing to large-scale industries like aerospace and automotive manufacturing. 

Exposing students to activities like investment casting provides valuable experience with industry-standard manufacturing techniques,  giving students an advantage when they begin looking for jobs. 

Understanding manufacturing techniques is also essential for engineers who must be knowledgeable about the materials and production methods used in various industries. Additionally, investment casting introduces students to skills applicable in various STEM careers. 

Even for students who may not pursue a direct career in manufacturing or engineering, learning investment casting can be beneficial in fields such as dentistry and jewelry making. More than just a techni

cal skill, investment casting fosters creativity, problem-solving and a deeper appreciation for the role of manufacturing in everyday life.

A Hands-On Learning Experience

Investment casting is just one of the many techniques METAL workshops cover to introduce students to casting, forging, manufacturing and design.

Engaging students in these hands-on manufacturing processes fosters an understanding of traditional metalworking techniques. 

The ability to transform an idea into a tangible object provides both practical skills and a sense of accomplishment. 

Stay tuned for more workshops and opportunities to get involved in the world of metals! If you’re interested in learning more or hosting your own workshop,contact us here: https://www.metalforamerica.org/contact-us/

About IACMI:

IACMI-The Composites Institute® is a 170-plus member community of industry, colleges and universities, national laboratories, and government agencies working together to benefit the nation’s energy, manufacturing, and economic security. IACMI is managed by the Collaborative Composite Solutions Corporation (CCS), a not-for-profit organization established by The University of Tennessee Research Foundation. A Manufacturing USA institute, IACMI is supported by the U.S. Department of Energy’s Advanced Materials Manufacturing Technologies Office, as well as key state and industry partners.

The University of Tennessee, Knoxville (UTK) recently hosted a METAL bootcamp designed to inspire and prepare the next generation of metallurgical engineers and tradespeople. METAL—short for Metallurgical Engineering Trades Apprenticeships and Learning—is a workforce development initiative led by IACMI-The Composites Institute aimed at addressing critical shortages in the U.S. defense industrial base within the forging and casting industries. The bootcamp serves as a hands-on introduction to metallurgy, giving participants a unique opportunity to learn, experiment, and envision a future in a vital field. 

“I am excited about this new partnership between the College of Arts and Sciences School of Art Sculpture program and the Tickle College of Engineering and Materials Science department,” said Jason Brown, a UT art professor who worked with IACMI to facilitate the METAL bootcamp at the university.  

“The IACMI METAL bootcamp is creating new opportunities for University of Tennessee students and faculty to share research and teaching focused on metalcasting and metallurgy. This workforce readiness program also extends our academic training and research into the community through the land grant mission of UT.”

University Students Discover a Passion for Metal

University of Tennessee School of Art foundry consultant Ronda Wright was also instrumental in the METAL bootcamp, preparing, advising and working with participants of various backgrounds as they learned to cast metal. 

“I think my first iron pour was in about 2005, and I was immediately captivated,” Wright said. 

The experience ignited her passion in foundry processes, from mold making to operating the furnaces and pouring molten metal. After pouring iron for the first time, she switched her undergraduate major at the UT to a Bachelor of Fine Arts, focusing on metal sculpture. While still in school, she began doing iron and bronze pours at community events around the country.

After graduation, she continued in professional practice, opening a metal shop in Knoxville that focused on metal fabrication, casting and forging. She attended graduate school at Alfred University in New York before returning to the UT as a senior academic and professional development advisor, visiting studio artist, lecturer and foundry consultant. 

“The METAL bootcamp was a unique opportunity here because it highlights the importance of engineering, craft, skilled labor and manufacturing,” Wright said. “My educational path was a long journey. I was unaware of the many opportunities in professional foundry and welding that don’t require a degree in higher education. It is important in academia to acknowledge and support other paths in successful and fulfilling careers in industry-led fields like metal work.”

Metallurgy plays an essential role in the modern world, powering industries from aerospace to renewable energy. However, a growing skills gap threatens the sector’s ability to meet demand. The METAL bootcamp is specifically designed to tackle this issue by engaging students, recent graduates, and early-career professionals in an immersive educational experience.

The event featured a mix of classroom instruction, hands-on skills building, and collaborative problem-solving activities. Participants explored topics such as metal properties, heat treatment processes, and the role of advanced manufacturing techniques in the industry. Through these experiences, attendees not only gained technical skills but also a broader appreciation for metallurgy’s role in shaping innovation.

“My encounter with the METAL bootcamp was such a great experience,” said Francis Akosah, a graduate student at UT’s School of Art. 

Akosah began working in metal art in Ghana, before moving to the United States to pursue his master’s degree in fine arts. Akosah assisted Wright in leading bootcamp sessions while participating as well. 

“I especially enjoyed working with the engineers and learned a lot from them,” Akosah said. “We approach metal pouring with two different methods — artists are more traditional and engineers are more contemporary. It was like two languages, but everyone was able to understand each other’s language and collaborate. I am looking forward to more opportunities to collaborate with technicians and engineers to better understand the manufacturing challenges.”

Why METAL Matters

As the U.S. seeks to strengthen its manufacturing base, programs like METAL are critical for building a skilled workforce capable of meeting current and future demands. The forging and casting industries are cornerstones of the defense sector, and their success depends on a steady influx of talent. 

METAL bootcamps not only address immediate workforce needs but also foster a sense of community among participants. Attendees leave with a clear understanding of how their work could contribute to a larger mission, from creating stronger materials for infrastructure to enabling technological innovations.

Whether you’re a student considering a career in engineering, a professional looking to reskill, or an educator seeking to inspire your students, the METAL initiative offers resources and opportunities to get involved. Together, we can forge a brighter future for metallurgy and the industries it supports.

To learn more about upcoming METAL bootcamps and other opportunities, visit MetalforAmerica.org or follow them on social media for updates. Let’s build the workforce of tomorrow—one bootcamp at a time.