Foundry Talk

Join hosts Perry Merritt and Nate McLain on the Foundry Talk podcast for a lively conversation with Jim Gauldin, President of Palmer Manufacturing. Jim traces Palmer’s roots back to a small evening foundry run by Jack Palmer and his father, where building their own sand mixer for speed led to an unexpected sale that sparked a full equipment-manufacturing business. The discussion highlights Palmer’s innovative Flip Mold Machine (FMM), a compact all-in-one rollover/carousel design that boosts production cadence, saves floor space, and reduces operator fatigue—with growing installations and strong customer feedback. They explore Palmer’s diversification into rail traction sand systems, golf course sand reclamation, and more. The conversation dives into Foundry 4.0—predictive sensors, data connectivity, AI possibilities, cybersecurity concerns, and the real challenges of adoption in small-to-large foundries. Heartfelt stories celebrate the larger-than-life Jack Palmer—his creativity (including casting his own face in aluminum), boundless energy, and enduring legacy. A great listen for anyone in metal casting interested in practical innovation, equipment evolution, and the future of the industry. Listen now and visit https://palmermfg.com/ for videos, equipment details, and Simple Solutions That Work magazine. #podcast #foundry #manufacturing #smallbusiness

Nate frequently says foundry people are "the salt of the earth," and this episode's guest certainly fits the bill. Join us as we sit down with Rick Buellesfeld, owner and operator of Sooner State Pattern Works in Blackwell, Oklahoma. Rick shares the story of founding his pattern-making business on New Year's Day 1989 after purchasing a shop, growing it from a small team to a dedicated crew of about eight, including family members like his son Randy (shop manager) and daughter Gayle (office manager). He reflects on the evolution from traditional manual layout work to embracing CNC machining since the early 1990s, tackling complex patterns for sand casting, investment casting, hydraulic components, impellers, diffusers, and even plastic injection molds. The conversation covers industry challenges like shrink variations, foundry-specific rigging, foreign competition, employee ideas and retention, the value of quality control, and the pride in building durable, precise tools that foundries and end-users rely on—delivering insights into the heart of American pattern-making and metal casting. #podcast #foundry #manufacturing #smallbusiness#podcast #foundry #manufacturing #smallbusiness

In this episode of Foundry Talk, hosts Nate McClain and Perry Merritt chat with Dave Schmidt, VP of Finite Solutions Incorporated, about metal casting simulation software. Dave shares the company's history since 1985, debunking misconceptions (yes, it works!), and demos flow/solidification analysis to predict defects, optimize rigging, and improve yields. They explore real-world examples like turbulent fills, bottom gating issues, and how simulation aids robust processes—essential for modern foundries. Tips on using tools like SOLIDCast, plus contract services for those without in-house expertise. Contact: [email protected] or (262) 644-0785. Visit finitesolutions.com for more. #podcast #foundry #manufacturing #smallbusiness

In this episode of Foundry Talk, hosts Nate McClain and Perry Merritt talk with Bill Crouse of ProTech Pattern in rural Wisconsin. Bill shares his path from freelancing in 1996 to opening his dream shop in 2018—built right next to his home for ultimate convenience (and occasional work-home blur). They discuss running a small, fast-response pattern shop: long hours, quick turnarounds, CNC machining, laser scanning for quality, and exploring 3D printing for gating and cores. Bill covers the shift from traditional bench work to modern CAD and additive tech, plus the value of self-taught problem-solvers. Full of practical tips and passion from a dedicated small-shop operator—perfect for foundry folks and patternmaking enthusiasts. #podcast #foundry #manufacturing #smallbusiness

The Foundry Talk Podcast is back for a brand new season. Join us Monday February 9th as we start talking to new guests.

Think you know how much bronze it takes to make memorial markers? In this episode, we talk with Dave Rittmeyer of Matthews International and get a surprising answer about the sheer volume of metal used for grave markers and other memorials. Dave gives us a fascinating look into the production process, from traditional hand-setting of letters to modern 3D printing, and shares his personal mission to "bridge the gap between art and industry" by connecting industrial arts and fine arts at universities. He also discusses the evolving culture of the foundry world, which has shifted from an "isolationist" past to a more collaborative and helpful community today. #podcast #foundry #manufacturing

In this episode, hosts Perry and Nate sit down with Dan Weiss, the president of adatasol, to uncover his fascinating journey into the tech world. Dan shares how his company evolved to build custom database solutions, specifically for "visionary" business owners frustrated with their current software. The conversation is a must-listen for anyone running a business, as they explore the hidden dangers of using spreadsheets and the undeniable value of data. Tune in to learn how this approach helps them rapidly build powerful solutions, making live changes with clients to create the perfect software solution.https://adatasol.com/#podcast #foundry #manufacturing #smallbusiness

Get ready to refine your knowledge! This episode, we're sitting down with Bryan Davis, the National Sales Manager at Remelt Sources, to pull back the curtain on certified metal alloys. We'll unpack the mysteries of AOD and VOD refinement, discover the magic of continuous pour casting, and perhaps most importantly, finally get to the bottom of "what the heck is a forehead versus an eight head?" Join us for a lively discussion that promises to be as informative as it is engaging. #podcast #manufacturing #metalcasting #foundry

Join us for a special episode with Professor John Campbell, a renowned, influential, and controversial figure in the foundry industry. We'll delve into the critical challenge of bi-film and its impact on casting quality.Professor Campbell will share groundbreaking pouring techniques and practical strategies from his extensive research, revealing remarkable progress toward achieving zero bi-film castings. This isn't just theory; it's about real-world results set to redefine foundry standards.Professor Campbell was an absolute treat, you won't want to miss this episode.https://www.aspect-design.net/product-page/mini-castings-handbookhttps://hub.afsinc.org/NC__Product?id=a2Z1a000000YgfHEAShttps://www.researchgate.net/publication/286465194_Hoyt_memorial_lecture_-_Stop_pouring_start_castinghttps://youtu.be/9_w3OZ2b02A?si=vClfRLByp5RGMN1_ #podcast #foundry #manufacturing #smallbusiness

Are regulations "choking" American foundries? On Foundry Talk, we speak with Jerrod Weaver of NFFS.org about the critical challenges facing the industry. We'll discuss the impact of regulations and why targeted tariffs are crucial over blanket ones. How can U.S. foundries compete and thrive in a low-priced global market? Jerrod shares NFFS's strategies for success. If you're interested in American manufacturing, supply chain resilience, and the future of a vital industry, tune in for insights into the metal casting world's challenges and solutions. #podcast #foundry #manufacturing #smallbusiness

Join Nate McLain and Perry Merritt as they talk with Todd Yoder, Additive Manufacturing Manager at Hoosier Patterns. Get an inside look at 3D printed molds and cutting-edge 3D sand printing technology. Discover how Hoosier Patterns delivers top-tier quality by valuing customer feedback and fostering exceptional employee engagement. #podcast #foundry #manufacturing #smallbusiness

Just how "green" is the foundry business? Dive into the surprising world of sustainable metal production with us! In this episode, we chat with Chris Greenfield of the Federal Metal Company about the critical role of metal recycling and the intricate process behind creating and supplying certified alloy ingots. Discover how innovation and responsible practices are shaping a more environmentally friendly future for the industry. #podcast #foundry #manufacturing #smallbusiness

Ready to hear the unfiltered truth about building a business from the ground up? Meet Tim Carr, a.k.a. "Abrasive Tim," the straight-talking founder of Cutting Edge Abrasives. Forget the sugarcoating – Tim shares the gritty details of launching his company and the relentless dedication it takes to keep it thriving. Discover the no-nonsense strategies and customer-first philosophy that drive his success. If you're looking for real insights into the world of entrepreneurship, buckle up and tune in. Contact Tim: https://cuttingedgeabrasives.com/ Phone 1-866-968-4144

Get ready for laughs and valuable insights! We had a fantastic time chatting with Clarke Easterling from Windy Hill Foundry in Mississippi. Tune in as we explore the ups and downs of entrepreneurship, the intricacies of furnace design, and the unexpected issues that come with canine companions. #podcast #foundry #manufacturing #smallbusiness

If you're into metal, art, or just plain cool stories, you'll love this podcast! With nearly 80 years of experience between them, Tony and Nate geek out on foundry techniques. Tony has been running Art Castings of Colorado for over 30 years, turning it into a place where artists from all over the world come to make their visions a reality. Oh, and they also cast a seriously famous sports trophy. Want to know which one? Listen in as Tony shares his amazing story.Visit http://artcastings.com to see the work Tony's team does

Join us as we have a broad conversation with Julie Markee, Managing Director of Key Process Innovations. We talk chickens (yes chicken), investment casting, business process, and the wide range of opportunities that exist for employment in the foundry world. Julie's web sites include https://www.keyprocessinnovations.com/ and of course her thoughts on chickens https://www.keyprocessinnovations.com/news-2/. Be sure to check out the kpi-dry® Investment Casting Shell Monitor while you're there.

Jerrod Weaver Executive Director Non-Ferrous Founder's Societyhttp://nffs.org joins us to talk about the growing need for employees in the foundry industry and sheds light on the efforts NFFS is doing to get the word out and attract younger employees to the business.Help support the podcast and check out our merch https://foundry-talk.myspreadshop.com/. Word to the wise, buy a size larger than you think 😄

What Foundry Talk is all about.

Get to know the hosts of Foundry Talk. Nate and Perry spend some time introducing themselves and generally having a good time while they do it. In this episode you'll get to know their backgrounds and how they came together to start this podcast. They look forward to hearing from you. Episodes with video are available on the Foundry Talk YouTube channel.