Foundry 4.0

Digital Manufacturing in the Metalcasting Industry

Eaglewood Resort
June 9-10, 2020


What will a foundry look like in 10 years?

The designation ‘‘4.0’’ is often used in reference to the next phase of the Industrial Revolution (the “Fourth Industrial Revolution”) and generally expresses the impact of smart manufacturing and the implementation of technology in manufacturing. 

This conference will focus on how digital manufacturing is affecting all areas of the casting  process today, and how this will change the foundry of the future. Key seminar topics are data collection and management, data-driven decision-making, artificial intelligence, augmented reality, virtual reality, wearable technology, robotics, automation, and cyber security, as well as the related issues of workforce development, recruiting, and training. The conference will include foundry case studies demonstrating how implementation of data collection, automation, and digital technologies have changed and improved operations today.



  • Eaglewood Resort
  • Itasca, IL (near O'Hare International Airport)
  • June 9-10, 2020
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Hotel Information

  • Eaglewood Resort & Spa
  • Itasca, IL
  • $157.00


Diran Apelian
Professor of Materials Science and Engineering, University of California

Diran Apelian is the Professor of Materials Science and Engineering at University of California, Irvine and heads the advanced material processing activities of the Institute for Design and Manufacturing. Apelian is also the Director of the Advanced Casting Research Center at Worcester Polytechnic Institute. Apelian is a Fellow of The Minerals, Metal, and Materials Society, ASM, and American Powder Metallurgy Institute. He is a member of the National Academy of Engineering (NAE), National Academy of Inventors (NAI), European Academy of Sciences, and the Armenian Academy of Sciences. Apelian was TMS President (2008/09) and Chair of the ASM Educational Foundation Board (2016/2018). He is a co-founder of Solvus Global LLC, Battery Resourcers Inc., Kinetic Batteries LLC, and Melt Cognition LLC.

Mike Bartels
Director of Research, Tobii Pro

Mike Bartels is the Director of Research at Tobii Pro in North America.  He has over 15 years experience studying human visual attention across a variety of different contexts, including training, performance, usability, and design. Bartels has a master’s degree in experimental psychology and has written extensively on eye tracking technology.

David Blondheim
Engineering Manager, Mercury Marine

David Blondheim Jr. earned a BS in mechanical engineering from Michigan Technological University, a MBA from University of Wisconsin-Oshkosh, a MS in industrial engineering from Purdue, and is working on his PhD in systems engineering through Colorado State University. His research focus is the application of big data and machine learning algorithms to the diecasting manufacturing process and equipment to improve decision making within the industry. Blondheim is currently the Engineering manager at Mercury Marine and is leading the Connected Operations/IIoT efforts across all Mercury operations.

David Gilson
Sales and Marketing Director, SinterCast

David Gilson is the sales and marketing director at SinterCast, a precision measurement and technology provider for compacted graphite iron production and foundry tracking processes. Gilson currently serves on the AFS National Board of Directors and was past chair of the AFS Cast Iron Research Committee. He has previously served on the board of directors for the Ductile Iron Society and as chair of the DIS Marketing Committee. Gilson is also active in the Society of Automotive Engineers, most recently serving as chair for the SAE COMVEC 2019 Powertrain Committee. He has written several technical papers for industry publications and presented on a variety of topics for local, regional, and global foundry industry conferences.

Melissa Glossup
Co-founder and CEO, KOSTechnology

Melissa Glossup is the co-founder and CEO of KOSTechnology. She is passionate and highly committed to workplace safety. As a leader in innovation, she is leading the way to use wearable biometric technologies to create smarter, safer industries, and improve organizational operation and employee experience.

Ryan Larson

Ryan Larson is a licensed professional engineer with over 15 years of industrial structural design experience. For the past decade, he has led the laser scanning and industrial design division of ZS LLC. He holds a Bachelor and Master of Science degrees in Engineering from the University of Wisconsin – Milwaukee and is currently licensed in eight states.

Federico Sciammarella
President & CTO, MxD

Federico Sciammarella serves as the president & CTO of MxD. Sciammarella was previously an associate professor at Northern Illinois University, where he directed the Advanced Research in Materials and Manufacturing for more than 10 years which generated over $2.5 million in funding and created a launch pad for many students and technologies in advanced manufacturing. He has a long list of publications and patents for applications in laser assisted machining and additive manufacturing.

Jiten Shah
President, Product Development Analysis, LLC

With over 30 years of casting design and manufacturing experience, Jiten Shan has been a member of and involved with various research projects by key manufacturing innovation institutes – MxD, LIFT and America Makes – over the last 6 years.

Craig Truempi
Adjunct Professor, University of St. Thomas.

Craig Truempi is a published author of 30-plus articles on predictive maintenance, artificial intelligence and internet of things. Truempi is a certified maintenance and reliability professional, certified reliability leader, board member of the Upper Midwest Chapter of the Vibration Institute, and adjunct professor at the University of St. Thomas.

David Weiss
Vice President of Engineering and R&D, Eck Industries

David Weiss is vice president of engineering and R&D for Eck Industries and is responsible for development and application of high-performance alloys and casting concepts for the foundry and its customers. Weiss has authored over 70 papers on the processing and application of aluminum, metal matrix composite, and magnesium castings. He has won numerous industry awards including the John A. Penton Gold Medal from the American Foundry Society for pioneering work in the premium aluminum casting industry.  

Cayla Zielinski
Comau North America

Cayla Zielinski is responsible for the MATE exoskeleton product for Comau North America.  She is a graduate of the University of Michigan with a BS in biology.

Conference Agenda

Monday, June 8, 2020
3 - 4 p.m.
Conference Pre-Registration
4 p.m.
Golf tee times available

(Sign up directly through Eaglewood Resort)

Tuesday, June 9, 2020
7 a.m.
Registration Opens / Breakfast
8 - 8:15 a.m.
Conference Starts / Introductions

Doug Kurkul, Steve Robison AFS, Schaumburg IL

8:15 - 9 a.m.
The Future of Work and the Worker: Challenges and Opportunities for Manufacturing and Foundry Industries

Diran Apelian, Advance Casting Research Center, Worcester Polytechnic Institute,  Worcester MA

9 - 9:30 a.m.
Artificial intelligence

David Wang, Beet Mfg 

9:30 - 10 a.m.
Data-Driven Decision-Making Using Sensors and Controls

Jim Wenson, Sinto America, Lansing MI 

10 - 10:30 a.m.
10:30 - 11 a.m.
Collecting and Analyzing Time-Series Data for Process and Predictive Maintenance

David Blondhiem, Mercury Marine, Fond Du Lac, WI

11 - 11:30 a.m.
Capturing Unknown Variables using AI for Better Process Control

Jiten Shah, Product Development and Analysis, Naperville IL

Frank Headington, American Foundry Society, Schaumburg IL 

11:30 a.m. - 12:15 p.m.
12:15 - 1 p.m.
Special Presentation The Developing Digital Age: Cultural Changes That Will Impact Manufacturing

Mike Lakas, AFS, Schaumburg IL

1 - 1:20 p.m.
Laser Scanning and BIM for Complex Industrial Installations

Ryan M. Larson, ZS LLC, Milwaukee, WI

1:20 - 1:40 p.m.
Casting Quality Prediction via Supervised Machine Learning

Adam Kopper, Mercury Marine, Fond Du Lac, WI 

1:40 - 2 p.m.
IoT and Sensors for Improving Predictive Maintenance and Reliability in a Permanent Mold Foundry

Craig Truempi, ATEK Access Technologies, Eden Prairie MN 

2 - 2:20 p.m.
2:20 - 2:40 p.m.
How a Permanent Mold Foundry is Taking the 4.0 Turn Towards Data-Driven Melt Quality and Casting Process decision making: Now What’s Next?

Yohan Tremblay, Foundry Solutions and Metallurgical Services, Magog, QC, Canada

2:40 - 3 p.m.
Process Control and Traceability for The Foundry Industry

David Gilson, SinterCast, Brookfield WI

3 - 3:40 p.m.
Attracting, Hiring and Managing Personnel in the New Manufacturing Environment

Joey Leonard, HS Group Hr Inc, Green Bay, WI

3:40 - 4:20 p.m.
Open Forum on Workforce Development and Training
4:20 - 4:40 p.m.
Q&A wrap-up
5:30 - 7:30 p.m.
Networking Reception: Exhibits and Demonstrations
Wednesday, June 10, 2020
7 - 8 a.m.
8 - 8:45 a.m.
Digital Twins, Cyber Security and Digital Manufacturing for the Metalcasting Industry

Federico Sciammarella, MxD, Chicago IL

8:45 - 9:15 a.m.
Exoskeletons for Ergonomics

Cayla Zielinski, Camau, Southfield, MI 

9:15 - 9:45 a.m.
Wearable Biometrics to Monitor Employees for Heat Stress & Fatigue

Melissa Glossup, KOSTechnology, Long Beach, CA

9:45 - 10:15 a.m.
Case Study: Eye Tracking Glasses for Training Metal Pourers

Mike Bartels, Toby Younis, Tobii Pro, Reston, VA

10:15 - 10:45 a.m.
10:45 - 11 a.m.
Flexible Casting Cleaning in a Robotic Cell

Dave Weiss, Eck Industries, Manitowoc WI

11 - 11:15 a.m.
Robotic Pouring and Placement of Cores

Hideki Gebken, Standard Manufacturing, Winnipeg Manitoba, Canada 

11:15 - 11:30 a.m.
Mechanical Arm Design for Dipping or Coating

Randy Oehrlein, Carley Foundry, Blaine MN 

11:30 - Noon
Case Study: Augmented Reality for Equipment Maintenance and Training

Peter Reich, Laempe Reich, Trussville AL

Noon - 1 p.m.
1 - 1:30 p.m.
Virtual Reality for Interactive Training

John Moreland, Purdue University Northwest, Hammond IN

1:30 - 2 p.m.
Customer Perspective: Lockheed Martin’s Future Vision for Foundries

Bill Harris, Heather Woodworth, Sikorsky, A Lockheed Martin Company

2 - 3 p.m.
Achieving Real-Time Process Monitoring During Sand Castings with Additive Manufacturing and Wireless Sensors

Jason Walker, Eric MacDonald, Youngstown  State University, Youngstown, OH 

Kirk Rogers, M&P Gravity Works, Youngstown, OH

3 – 4 p.m.
The Foundry in a Starship; Melting and Pouring in a Zero Gravity Atmosphere

Dave Weiss, Eck Industries, Manitowoc, WI

4 p.m.
Conference Concludes


Registration Fees

Early registration: Non-member: $1,225.00 | Member: $850.00 (ends May 17, 2020)

Standard Registration: Non-member: $1,425.00 | Member: $1,050.00

Cancellations & Substitutions

Substitutions will be accepted anytime. However, cancellations of confirmed registrants with full refund of fees will not be accepted unless received at least two weeks prior to the conference date. In the unlikely event the conference is cancelled for any reason, AFS liability is limited to the return of the registration fee.