The Casting Crisis: How Next-Generation Technologies Are Restoring US Manufacturing

The American manufacturing industry is facing a casting crisis. In just 5 years, most of our experienced foundry workforce will retire, taking with them decades of specialist knowledge. Over 70% of foundries across the US have closed since 2015. Whether it’s maintaining aging defense systems or advancing new military technologies, casting bottlenecks are slowing production, increasing costs, and compromising military readiness.

The situation is critical. Delays in securing essential components are threatening mission timelines and national security. With fewer casting options available, manufacturers are forced to either pay prohibitive costs for retooling or accept compromises. Additionally, dependence on unpredictable global supply chains only heightens the risk, leaving U.S. defense manufacturing vulnerable.

We don’t need an alternative; we just need castings.

In this presentation, we will address the severity of the casting crisis and its impact on the defense industry. We will also explore how Foundry Lab’s digital casting technology provides an immediate and scalable solution. Attendees will learn how the DMC-3 system can help defense contractors maintain operational readiness, reduce production costs, and deliver innovative solutions without compromising on time or quality.

Learning Objectives:
Analyze the impact of the U.S. foundry collapse on domestic manufacturing and supply chains.
Understand how next-gen tooling technologies can restore sovereign manufacturing capabilities.
Explore digital casting systems as a means to reduce production timelines and costs while maintaining quality.
Learn how in-house casting technology can address labor shortages and secure critical supply lines, particularly in defense and high-stakes industries.

This presentation offers actionable insights for defense manufacturers seeking to future-proof their operations and reassert control over their production capabilities.