Reference Quantity: ST0566

Particulars of normal

Occupational Profile

Steel Casting, Foundry and Patternmaking Technicians are concerned in extremely expert, complicated and necessary roles within the Forged Metals Business.  The UK trade is a contemporary and superior sector, producing 530,000 tonnes of castings in all metals with an annual worth of £2.2 Billion and the 400 foundries make use of greater than 17,000 Operatives, Technicians, Engineers, Supervisors, Managers and Workers.  Castings might weigh lower than a gramme or over 600 tonnes. The trade underpins and is a crucial provider to different industries (automotive, aerospace, rail, energy and renewable power, medical, pumps & valves, defence, petrochemical and marine). 

Technicians could be employed in all sizes of firms, working independently or as a part of a group in a foundry, workshop or laboratory.  A watch for element is important they usually might want to adjust to security necessities.

Frequent Technician job titles are: Sample and Mannequin Making or Strategies Improvement Technician who plan tips on how to design and make patterns in wooden, resin or metallic from 2D/3D drawings, typically utilizing additive manufacturing strategies and simulation software program programmes, to supply prototypes or pattern castings to tight tolerance; Foundry Materials and Course of Management Technician, Foundry Manufacturing or Steel Casting Furnace and Ladle Technician who put together and management sand or liquid metallic high quality for casting into moulds or dies, which can contain upkeep and management of complicated automated gear; Publish Casting Technician; Inspection, Non-Harmful, Mechanical Testing and High quality Assurance Technician who examine and perform and file management exams on samples or castings to fulfill agreed tolerances. To be occupationally competent, the core information, abilities and behaviours listed beneath have to be achieved, plus information and abilities from one of many specialist choices.

CORE KNOWLEDGE: wants to grasp:

  • Related statutory, high quality, environmental compliance procedures and techniques, organisational and well being and security laws regarding manufacturing operations.
  • Their particular person roles and obligations inside the organisation and the boundaries of their very own authority and the implications of working outdoors of this.
  • Find out how to interpret related engineering and manufacturing knowledge and documentation to execute their job function, i.e., tips on how to perceive a 2-dimensional engineering drawing and use this to supply a three-d mannequin.
  • The final Steel Casting, Foundry and Patternmaking manufacturing mathematical and scientific ideas, strategies, strategies, graphical expressions, symbols formulae and calculations utilized by this engineering setting. i.e. tips on how to perceive contraction allowances within the calculation of technical drawings for particular sample manufacturing or the temperature specs of casting liquid metallic.
  • The construction, properties and traits of frequent supplies used within the sector for instance: Sample Making supplies like totally different woods, metals and plastics, Foundry Sand, Binders, Coatings, Feeding and Filtration Methods, Refractories, Varied Steel Alloys, Components, Waxes and Lubricants. Laboratory Testing together with: Sand and Binder Properties, Chemical Composition and Mechanical Testing i.e.: Tensile and Hardness Testing.

  • The total course of of manufacturing castings from a technical drawing to a completed casting they usually will need to have information of the manufacturing practices, processes and procedures.

CORE SKILLS: wants to have the ability to:

  • Apply protected techniques of labor, complying with well being and security laws, laws, environmental compliance procedures and techniques and different related tips.
  • Show clear and efficient communication abilities which embrace oral, written, digital and visible shows.
  • Plan and procure all of the sources and documentation required to undertake the manufacturing course of i.e. a technician would plan and put together the method to supply prototype castings. All parts and steps can be required to be deliberate, sources would have to be briefed and all levels of manufacturing recorded.
  • Undertake the work utilizing the right processes, procedures and gear. i.e. the ultimate inspection of an entire casting previous to despatch to make sure it complies with buyer specs.
  • Carry out security, high quality and compliance checks, utilizing the right processes, procedures and gear. i.e.: making certain the gravity die meeting is protected and able to begin manufacturing.
  • Full applicable documentation in an correct, environment friendly and legible method through the use of the right terminology.
  • Preserve a constructive working relationship with a spread of individuals working inside the manufacturing setting.
  • Deal promptly and successfully with Casting, Foundry or Patternmaking issues inside the limits of their accountability utilizing authorized diagnostic strategies and strategies and report these which can’t be resolved.
  • Work effectively and successfully, sustaining office organisation and minimising waste.


The Steel Casting, Foundry and Patternmaking trade, require their apprentices to have a set of behaviours that’s according to the Engineering Council’s tips to make sure success in each their function and within the general firm targets. 

  • Private accountability and resilience – Adjust to the well being and security steering and procedures, be disciplined and have a accountable method to danger. Work diligently whatever the stage of supervision, settle for accountability for managing time and workload and keep motivated and dedicated when going through challenges.
  • Work successfully in groups – Combine and contribute with the group, assist different folks, think about implications of their very own actions on different folks and the enterprise while working successfully to get the duty accomplished.
  • Efficient communication and interpersonal abilities – An open and sincere communicator, communicates clearly utilizing applicable strategies, listens nicely to others and has a constructive and respectful angle.
  • Concentrate on high quality and drawback fixing – Observe directions and steering, reveal consideration to element, observe a logical method to drawback fixing and search alternatives to enhance high quality, pace and effectivity.
  • Steady private improvement – Replicate on abilities, information, behaviours and search alternatives to develop, adapt to totally different conditions, environments or applied sciences and have a constructive angle to suggestions and recommendation.

Choices for Specialist Job Roles:

Steel Casting, Foundry and Patternmaking Technician should full one of many following choices:

Choice 1: Sample and Mannequin Making Technician

Data – will know and perceive tips on how to

  • Learn and interpret knowledge from technical drawings and specs in a Patternmaking context.
  • Choose the right medium, like wooden, metallic, plastic or composite for the manufacturing of patterns and fashions, contemplating the economics and finish use setting.

Talent – will have the ability to

  • Use mechanical and hand instruments mixed with specialist gear which is more likely to embrace equipment corresponding to Vertical Milling Centres, to supply elements with minimal supervision.
  • Adjust to the specification and high quality necessities as outlined on appropriate technical drawings for wooden, metallic and plastics supplies.

Choice 2: Strategies Improvement Technician

Data – will know and perceive

  • All of the related bodily processes and traits of the manufacturing course of in metallic casting foundries
  • Find out how to use simulation know-how to foretell (quantitatively) all properties related to fulfill prospects’ specification and importantly, to supply a sound casting in essentially the most economical method.

Talent – will have the ability to

  • Manually calculate and produce an entire simulation together with, runner, gating design and feeding choices to make sure a top quality casting utilizing the economical manufacturing technique in varied metals and manufacturing processes.
  • Consider and clear up manufacturing points and casting failures in varied metals through the use of drawback fixing strategies associated to the working, gating and feeding of castings.

Choice 3: Foundry Materials and Course of Management Technician

Data – Will know and perceive

  • Analytical testing procedures and tips on how to create informative experiences.
  • Should have the ability to confer with printed ‘requirements’ and perceive their relevance to the supplies and processes.

Talent – will probably be required to:

  • Organise, consider and report outcomes utilizing the suitable testing gear to validate that supplies and processes are to Worldwide and Nationwide specs in addition to the shopper necessities.
  • Have the ability to consider, monitor and handle technical specs of manufacturing processes, casting alloy compositions and completed casting specs.  

Choice 4: Foundry Manufacturing Technician

Data – Will know and perceive

  • Manufacturing processes together with moulding, core manufacturing, die casting, funding casting and what’s required to keep up these.
  • Find out how to optimise efficiency and tips on how to react if issues go fallacious and the right stage of authority.

Talent – will probably be required to:

  • Optimise the manufacturing course of to enhance the efficiency of the manufacturing course of for complicated moulds, dies and assemblies bearing in mind high quality and financial components.
  • Make sure that the significance of economic ideas are recognised within the manufacturing course of for the fee efficient manufacturing of match for ourpose castings.

Choice 5: Steel Casting Furnace and Ladle Technician

Data – Will know and perceive

  • Find out how to calculate the cost formulation, the consequences of alloy or different metallic therapies and additive additions.
  • The assorted melting choices and molten metallic management and transportation strategies to realize the required remaining casting specification.

Talent – will probably be required to

  • Optimise the manufacturing course of to enhance the efficiency of the melting, soften switch and casting course of bearing in mind high quality and power effectivity course of to realize steady enchancment in efficiency.
  • Management the economics and technical functionality inside the melting, soften switch and casting manufacturing setting.

Choice 6: Foundry Publish Casting Technician

Data – will know and perceive

  • The ideas of key ‘Publish Casting’ operations which embrace, casting elimination from the mould, tough fettling, put up metallic casting warmth therapy i.e. stress relieving, annealing, normalising, quenching and tempering or answer therapy and getting old, casting restore, remaining fettling and machining.

Talent – will probably be required to:

  • Consider and calculate the right cooling charge, cleansing course of, warmth therapy sort, temperature and length, plus the fettling and casting cleansing course of.
  • When required, establish elements that require restore and element the method and technique to undertake the restore.
  • Calculate machining standards and the right machining processes for metallic castings that require machining.

Choice 7: Inspection and High quality Assurance Technician

Data – will know and perceive

  • The significance of high quality all through the casting manufacturing course of.
  • The information of Non-Harmful and Harmful testing gear and strategies and the capabilities and limitations of those strategies to high quality guarantee castings.

Talent – will probably be required to:

  • Undertake detailed Inspection and Testing actions utilizing specified strategies and gear.
  • To report findings regarding high quality and compliance to administration and to buyer specs and requirements.

Entry Necessities:

Particular person employers will set the choice standards for his or her Apprenticeships. Candidates will usually have 4 GCSEs at Grade C/4 or equal, together with Arithmetic, English and a Science.

Length of Apprenticeship:

Usually, 27-33 months


Apprentices with out stage 2 English and Maths might want to obtain this prior to finish level evaluation. For these with an schooling, well being and care plan or a legacy assertion, the apprenticeship’s English and Maths minimal necessities is Entry Stage 3, and British Signal Language {qualifications} are a substitute for English {qualifications} for these whom that is their major language.

Skilled Registration:

Completion of the Apprenticeship is designed to be recognised by the Institute of the Forged Metals Engineers to fulfill the necessities set out within the Engineering Council’s Specification for Engineering Technician to permit skilled registration.


This Apprenticeship Normal is at Stage 3


This commonplace will probably be reviewed after three years.

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