Why the Next Generation of Engineers Must Understand Investment Casting
In today’s competitive manufacturing landscape, it’s vital that young design engineers understand the strategic advantages of investment casting. This proven method not only improves performance and cost-efficiency but also supports national manufacturing resilience, especially in aerospace casting and defense applications. At Barron Industries, we are committed to educating the next generation of engineers on how precision castings can transform the way systems are designed, built, and supported.
Casting Knowledge Is a National Security Issue
Over the last several decades, the U.S. has outsourced much of its metal casting capability, leading to a steep decline in domestic expertise. Today, there is a critical shortage of investment casting companies, particularly those certified to rigorous standards like AS 9100 for aerospace suppliers. This is more than a supply chain issue, it’s a national security concern.
To combat this knowledge gap, Barron Industries hosts on-site casting seminars for engineers. These half- and full-day programs cover everything from dimensional tolerancing and non-destructive testing to material specifications and casting design principles. The results are striking engineers are eager to learn but often lack foundational knowledge because, so few universities still teach metal casting processes.
Investment Castings Deliver Major Cost Savings for Defense
Many prime defense contractors miss significant savings by defaulting to fully machined or fabricated parts, rather than exploring whether a component could be cast. While machined hogouts are easy to prototype, they are costly and material-wasteful in production. In contrast, investment castings can reduce part costs by as much as 50–90%, with only minimal additional collaboration during the design phase.
Barron Industries supplies over 200 investment cast components for the U.S. Army’s Stryker vehicle program. These parts, which were originally designed as fabrications, now save tens of thousands of dollars per vehicle. The scale of savings across hundreds of vehicles is massive and showcases the value of casting knowledge in reducing military cost.
Universities Must Re-Introduce Casting in Engineering Curricula
While technologies like additive manufacturing and 3D-printed metals are exciting and evolving, they are not currently scalable or affordable for many real-world industrial applications. Unfortunately, many universities are so focused on these emerging technologies that they’ve stopped teaching the fundamentals of casting, metallurgy, and materials engineering.
This oversight leaves engineering graduates unprepared to specify manufacturing processes that utilize nonferrous alloys, like A357 aluminum or other aluminum alloy castings, for lightweight, high-performance designs. Students should be learning both cutting-edge and time-tested technologies, casting is still essential to the modern manufacturing toolkit.
Today’s Metal Casting Is Powered by Cutting-Edge Technology
Contrary to outdated perceptions, investment casting is no longer a rudimentary process. Barron Industries employs state-of-the-art tools such as solidification modeling, fluid dynamics simulation, and digital design validation to predict and optimize part quality before production even begins.
Post-casting, our inspection and validation processes include:
- Real-time computed digital radiography
- Liquid penetrant and magnetic particle inspection
- Laser scanning and CMM metrology
- Advanced spectroscopy for chemical analysis
We integrate digital manufacturing with traditional craftsmanship, delivering precision casting solutions that meet the tightest aerospace and defense tolerances. When you visit our facility, you’ll see firsthand how modern foundry technology is shaping the future of American manufacturing.
Conclusion: Educating Engineers Today for the Manufacturing Challenges of Tomorrow
To build a strong future for American manufacturing, we must reinvest in metal casting education and help engineers understand how investment casting compares to other processes like 3D metal printing.
Barron Industries is proud to be at the forefront of this movement, equipping engineers with the tools, materials knowledge (from stainless steel to non-ferrous alloys), and collaboration opportunities they need to innovate effectively and affordably. Contact us today for all your investment casting needs.