The year 2030 is just five years away. The foundry of 2030 might look like today’s foundry at first glance, but a closer examination will likely reveal significant improvements and differences.

Automation. Foundry leaders tell us that the ongoing labor shortages leave them no choice but to continue to automate key functions. Well over 90% of foundries are making capital investments in 2025 and the top category is robotics, and, not surprising, the number of robotics firms that exhibited at CastExpo2025 was up compared to previous years. According to the March 2025 Quarterly Metalcasters Outlook Survey, 63% anticipate automation will have an increasing impact over the next three years, while 37% said no appreciable change. 

Industry 4.0. The American Foundry Society encourages foundries to invest in Industry 4.0 technology as part of a strategy to optimize operations and analyze the most important factory-floor information. Participation in the AFS Engineering & Smart Manufacturing Division, chaired by Greg Bray (EC&S), is free to AFS members and will allow you to interact with those on the leading edge of smart manufacturing for the foundry. In the March survey, 56% said they believe Industry 4.0 and smart manufacturing initiatives will play a greater role in our industry through 2028.

Additive Manufacturing. Recently, a foundry tragically burned and the patterns will need to be replaced using 3D printing. While that is an extreme example, 53% of foundry leaders who took our survey expect the impact of additive to continue to grow. AFS welcomes your involvement in the Additive Manufacturing Division chaired by Dave Rittmeyer (Matthews Additive Technologies) where you can continually learn best practices and hear about inspirational applications. 

Artificial Intelligence. AFS has brought AI to the world’s largest English-language metalcasting technical library. Many of our member companies are actively exploring how to apply AI to various aspects of their operations, customer service, and even financial forecasting. Some 52% of member foundries expect AI to play an increased role in our industry over the next several years. AFS’s AI Subcommittee, chaired by Zach Meadows (EC&S), meets six times per year and welcomes new members.

Reshoring. While the Trump administration’s tariffs policy is creating instability in key parts of American industry at the present time, the broader goal is to bring more manufacturing industries back to the U.S., from shipbuilding to technology. Significantly lower regulatory burdens and more predictable tax policies are expected to make the U.S. an even more attractive place to make things, despite challenges such as the worker shortage. Some 48% of AFS foundry leaders expect reshoring to have an increased impact on the metalcasting industry compared to 45% who expect no appreciable change––only 7% forecast a diminished impact. AFS supports The Reshoring Initiative, which assists manufacturers in calculating the total cost of reshoring versus retaining overseas suppliers.

Training. Reflecting the trends outlined above, foundries are needing better-trained employees who understand the metalcasting process and can think on their feet to quickly troubleshoot problems or identify solutions. The AFS Institute has seen a significant increase in the number of workers being trained over the past nine months. This trend also augurs well for the quality of castings going forward as well as the productivity of the foundry of the future.