Foundry Moulder
What is the work like?
As a foundry moulder you would make moulds to shape molten metal into castings. The castings would then be used to make parts for use in industries like aerospace and automotive engineering.
You would use different methods to make moulds, which could include:
- mixing sand with clay and water to make sand moulds, pressing it around a pre-formed shape before pouring in molten metal
- injecting resin into sand then heating it to form a hard shell (resin shell moulding)
- making a wax replica of the casting, applying heat resistant coatings, then melting the wax to leave the casting (investment or lost wax casting)
- putting loose sand into a polystyrene pattern, pouring molten metal into it then burning away the exposed polystyrene to leave the casting
- making moulds from heat resistant metals (die casting)
- bonding silica gel with ceramic powders by heating it to produce high quality precision castings (Shaw Process).
You might also make cores for moulds, which create a hollow space inside the casting when the molten metal is poured in (known as coremaking).
For some jobs, you may have to work with a team of moulders to make larger moulds, and you might make very large moulds by using specially designed sand pits in the foundry floor.
What qualifications and experience will employers look for?
You do not need specific qualifications to work as a foundry moulder. You could apply directly to a foundry or workshop to start as a foundry operative, then take training to progress to a job as a moulder.
You may also be able to get into this job through an apprenticeship scheme with an engineering company or foundry. The range of Apprenticeships available in your area will depend on the local jobs market and the types of skills employers need from their workers. For more information on Apprenticeships, visit www.apprenticeships.org.uk .
Alternatively, you could take a college course which would teach you some of the skills needed for this type of work. Courses include:
- BTEC First Certificate in Engineering
- BTEC National Certificate/Diploma in Manufacturing Engineering
- City & Guilds Certificate in Engineering
What further training and development can I do?
You could take on-the-job training leading to an NVQ qualification, including:
- Performing Manufacturing Operations levels 1 and 2
- Performing Engineering Operations levels 1 and 2
- Materials Processing and Finishing levels 2 and 3
- Engineering Woodworking, Pattern and Model Making Level 3.
With a Level 3 NVQ, you could improve your chances of promotion by applying for registration as an engineering technician (EngTech) with the Engineering Council.
See the Institute of Cast Metal Engineers website for more details about work-based training and qualifications.
Where can I go for more information?
National Metalforming Centre47 Birmingham Road
West Bromwich
West Midlands
B70 6PY
Watford
Hertfordshire
WD18 0JT
Tel: 0800 282167
If you would like to discuss your career options with a learning adviser, call 0800 100 900 or use our online enquiry form
Alternatively, you can visit our website at: www.direct.gov.uk/careersadvice
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What salary and other benefits can I expect?
- The starting salary for a foundry moulder is about £15,000 a year.
- With experience, this can rise to between £17,000 and £24,000 a year.
Figures are intended as a guideline only.
What are the hours and working conditions?
You would work for 37 hours a week, usually on a shift system which could involve nights and weekends.
This is a strenuous job and conditions can get very hot and dusty. You would be expected to use protective overalls, safety footwear and, when necessary, face shields and ear plugs.
What skills and knowledge will I need?
- attention to detail
- the ability to picture moulds from two-dimensional plans
- a methodical approach to work
- an understanding of casting principles and the properties of metals
- good communication skills
- good eyesight
- the ability to work on your own and as part of a team
- an awareness of health and safety.
What opportunities are there?
You can normally find opportunities in traditional industrial regions, for example South Yorkshire and the West Midlands.
If you have both machine and hand tool skills it may increase your chances of finding work.
With experience, you could progress to become a foundry workshop supervisor or manager. You could also train to become a technician, which can lead to a career in cast metals technology or mechanical engineering.
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