To an outside observer, foundries and the entire metal casting industry is one that changes little. The ore goes in, gets melted down, and parts come out. Steel beams, engine blocks, and dumbbells get produced using the same methods over and over. We know that perception couldn’t be further from the truth for anyone used to the foundry world. The fact is, we have been adapting to a changing industry and world ever since furnaces have existed.
From developing new types of furnaces to producing metal of greater strength and durability with less waste, finding ways to reuse sand castings, and adopting new machines to refine our products better before they go out the door, metal casting has a history of change and improvement.
Yet, it is fair to say that often change is hard. Sometimes, when we have been doing the same thing for too long, which can lead to complacency. When that happens, people don’t see change out on the horizon when it can be quickly dealt with, and they may not even see it when it comes up and hits them in the pocketbook. Unless a given foundry can adapt quickly, the results can be devastating.
That means the foundry world has to be constantly on the lookout for changes that will affect it before it becomes a crises situation. We find ourselves on the cusp of such a situation now.
Evolving Casting Technologies
The push towards greater sustainability is driving several new technologies as well as scrutiny into existing manufacturing practices. Everyone is familiar with the windmills that have cropped up anywhere there is enough flatland to build a dozen or so. Solar power is also becoming more popular as the panels come down in cost and increase in efficiency. Solar, in particular, isn’t being driven just by government initiatives but by consumer demand. Homesteading and other self-sufficiency movements have grown in popularity, including the desire to get electricity without hooking up to the grid. This presents an opportunity as both wind and solar technologies need new alloys that are strong and lightweight, alloys that foundries can develop and produce.
Emerging Market Opportunities
An even better opportunity is the rise of electric cars. Promised by many for many years, they are finally in production and becoming popular enough to make a dent. From the Prius to the Volt to the Tesla, electric cars are finally here, and they are making an impact. One significant and relatively obvious example is that fewer combustion engine vehicles are being sold. That, in turn, affects the foundry industry as electric cars don’t have engine blocks, which means we aren’t making as many. What electric vehicles do have, though, is a need to mount batteries. There will also be people who need their own charging stations and storage units for spare batteries. And of course, those same vehicles still have frames, drivetrains, rotors, and the like, just like any other car. No doubt, as these vehicles continue to grow in number, there will need to be additional infrastructure built. That means foundries will need to provide components for the charging stations that will either complement or replace gas stations. I would also be wise to begin exploring ways to repurpose or recycle gas tanks.
Acceptance of Change
Change comes, whether we want it or not. As we’ve seen, there are significant changes that are already well underway. For the metal casting industry to continue to thrive, we will have to do what we have always done, innovate, adapt and continue to serve the needs of our world.
