A Tiered Approach to Addressing the Need for a Skilled METAL Manufacturing Workforce: Hands-On and On-line Education and Training

Paul C. Lynch; Mark Rubeo; Christopher Henri Annear

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Conference: 2025 ASEE Annual Conference & Exposition
Location: Montreal, Quebec, Canada
Publication Date: June 22, 2025
Start Date: June 22, 2025
End Date: August 15, 2025
Conference Session: Manufacturing Division (MFG) Technical Session 2
Tagged Division: Manufacturing Division (MFG)
Tagged Topic: Diversity
Page Count: 19
Permanent URL: https://peer.asee.org/55407

Paper Authors

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Paul C. Lynch Pennsylvania State University Erie, The Behrend College

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Paul C. Lynch received his Ph.D., M.S., and B.S. degrees in Industrial Engineering from the Pennsylvania State University. Dr. Lynch is an associate professor of Industrial Engineering and Master of Manufacturing Management programs at Penn State Behrend. He is a member of AFS, AIST, SME, IISE, and ASEE. Dr. Lynch's primary research interests are in materials and manufacturing and engineering education.

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Mark Rubeo Pennsylvania State University, Behrend College

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Dr. Mark Rubeo is an Assistant Professor of Mechanical Engineering at Penn State Behrend. He received his B.S. in Mechanical Engineering from Penn State Behrend in 2012. He received his M.S. (2014) and Ph.D. (2016) in Mechanical Engineering from the University of North Carolina at Charlotte.

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Christopher Henri Annear Pennsylvania State University

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Abstract

Now more than ever, the United States casting and forging industries need to address a severe shortage of skilled workers. A pressing need exists to fill skilled professional roles in these industries that are critical to the U.S. national defense supply chain and national security for the United States. It has been estimated that by 2028, the United States will need to fill an additional 122,000 positions including: skilled tradespeople, engineers, and other critical manufacturing roles. To address this critical metal manufacturing workforce need, the Department of Defense Industrial Base Analysis and Sustainment (IBAS) Program has set out an ambitious plan to educate and create a highly-skilled workforce to sure up the U.S. defense industrial base. The METAL (Metallurgical Engineering Trades Apprenticeship & Learning) program is charged with carrying out this ambitious plan to educate and train from “K through gray” using a tiered educational approach to bring the next generation into the casting and forging industries while utilizing technology and innovation to solidly position these industries domestically for the future.

This paper discusses an innovative approach being taken by the Department of Defense IBAS Program and its partner organizations to provide the necessary recruitment, training, and education to provide a self-sustaining metal manufacturing workforce here in the United States well into the future. The paper will outline the hub and spoke model for the development and dissemination of training content and programs across the United States. The paper will discuss recruitment and training that is currently underway at (2) Levels: K-12 Workshops and Level 1 (Introductory Online and In Person BOOT CAMPS). The paper will also discuss (2) levels that are proposed and are currently under development: Level 2 (Industry Led Online and In Person BOOT CAMPS) and Level 3 (Metal Manufacturing Research & Technology Adoption Online and In Person BOOT CAMPS).

In addition to both hands on and online content being offered at multiple tiers or levels, the revitalization of apprenticeships across the casting and forging industries is also being carried out and is at the heart of the METAL mission to revive and advance the U.S. metal manufacturing industrial base.

Initial data and input collected from the initial METAL K-12 and Level 1 (Online and In Person BOOT CAMPS) will be presented along with the activities and curriculum/ content being carried out in these trainings.

Citation
Format

Lynch, P. C., & Rubeo, M., & Annear, C. H. (2025, June), A Tiered Approach to Addressing the Need for a Skilled METAL Manufacturing Workforce: Hands-On and On-line Education and Training Paper presented at 2025 ASEE Annual Conference & Exposition , Montreal, Quebec, Canada . https://peer.asee.org/55407

TY - CPAPER
AB - Now more than ever, the United States casting and forging industries need to address a severe shortage of skilled workers. A pressing need exists to fill skilled professional roles in these industries that are critical to the U.S. national defense supply chain and national security for the United States. It has been estimated that by 2028, the United States will need to fill an additional 122,000 positions including: skilled tradespeople, engineers, and other critical manufacturing roles. To address this critical metal manufacturing workforce need, the Department of Defense Industrial Base Analysis and Sustainment (IBAS) Program has set out an ambitious plan to educate and create a highly-skilled workforce to sure up the U.S. defense industrial base. The METAL (Metallurgical Engineering Trades Apprenticeship &amp;amp; Learning) program is charged with carrying out this ambitious plan to educate and train from “K through gray” using a tiered educational approach to bring the next generation into the casting and forging industries while utilizing technology and innovation to solidly position these industries domestically for the future.

This paper discusses an innovative approach being taken by the Department of Defense IBAS Program and its partner organizations to provide the necessary recruitment, training, and education to provide a self-sustaining metal manufacturing workforce here in the United States well into the future. The paper will outline the hub and spoke model for the development and dissemination of training content and programs across the United States. The paper will discuss recruitment and training that is currently underway at (2) Levels: K-12 Workshops and Level 1 (Introductory Online and In Person BOOT CAMPS). The paper will also discuss (2) levels that are proposed and are currently under development: Level 2 (Industry Led Online and In Person BOOT CAMPS) and Level 3 (Metal Manufacturing Research &amp;amp; Technology Adoption Online and In Person BOOT CAMPS).

In addition to both hands on and online content being offered at multiple tiers or levels, the revitalization of apprenticeships across the casting and forging industries is also being carried out and is at the heart of the METAL mission to revive and advance the U.S. metal manufacturing industrial base.

Initial data and input collected from the initial METAL K-12 and Level 1 (Online and In Person BOOT CAMPS) will be presented along with the activities and curriculum/ content being carried out in these trainings.

AU - Paul C. Lynch
AU - Mark Rubeo
AU - Christopher Henri Annear
CY - Montreal, Quebec, Canada
DA - 2025/06/22
PB - ASEE Conferences
TI - A Tiered Approach to Addressing the Need for a Skilled METAL Manufacturing Workforce: Hands-On and On-line Education and Training
UR - https://peer.asee.org/55407
ER -