Materials science and engineering students gain hands-on experience as part of a national manufacturing competition
Five engineering students put their design and manufacturing skills to the test in the Steel Founders' Society of America's Cast in Steel competition. The first season of the organization's YouTube series premieres on July 9.
The U.S. manufacturing sector is facing a major talent shortage. By 2030, 2.1 million jobs could go unfilled due to a lack of skilled labor. In the face of this shortage, Virginia Tech is preparing engineering students through hands-on learning experiences.
The most recent example? A national competition hosted by the Steel Founders’ Society of America. The competition and inaugural YouTube series called Cast in Steel challenges students from 38 university teams to design and manufacture cast-steel projects while gaining hands-on experience with engineering, manufacturing processes, and industry collaboration.
The challenge for this year’s competition was to create a replica of George Washington’s sword, and from the first pour of molten metal to the final test, Virginia Tech's team — named the Iron Maidens — was pushed to the limit.
"I learned so much about the full casting process from start to finish, which went way beyond what we typically cover in standard foundry classes,” said team lead and recent materials science graduate Ashley Lacy. “I gained experience working with a type of steel I'd never used before, and I even learned how to operate the overhead crane to pour molten metal directly from the furnace."
The Springfield, Virginia, native also commented on the unique experience of filming for the series.
"The filming process was a bit surreal at first, but the camera crew made us feel completely at ease and we even had the chance to meet David Baker and Ben Abbott from Forged in Fire," she said. "I loved having a platform to talk about a subject I’m so genuinely passionate about.”
Faculty advisor and recently retired director of the Kroehling Advanced Materials Foundry Alan Druschitz said, “Very few universities offer students the opportunity to take on projects like this that really prepares them for careers in manufacturing. This competition teaches the students cradle-to-grave design, manufacturing, and testing, all while working alongside industry partners.”
The first season of Cast in Steel premieres Thursday, July 9, at 8 p.m. EDT on YouTube and follows student teams from across the country as they compete in the national manufacturing challenge.
Watch the premiere and follow along with the Virginia Tech team’s journey on the Cast in Steel YouTube channel: https://www.youtube.com/@CastinSteel
