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2026 speaker profiles and presentations

All presentations remain the copyright of the contributing authors. 

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Andrew Turner, The World Foundry Organization

Andrew has a Metallurgy Degree from the University of Birmingham and a Post Graduate qualification in Production Management at the University of Cambridge.

Andrew joined Parkfield Group in 1982 in the melting department, becoming Technical Sales Director at the foundry in Stockton and, then in 1996 following great success with the securing of Channel Tunnel segment contracts worth over £40 Million, he was given the challenge of running the new Parkfield acquisition, Horwich Castings.

Following the collapse of the Parkfield empire in 1990, Andrew lead a management buy-out of the foundry from the administrators and stayed there until 1996 when he left to join Precision Disc Castings in Poole as Managing Director and oversaw the installation of the new DISA moulding line as part of a major expansion programme.

In 1999 Andrew Joined the then Institute of British Foundrymen as Secretary, having been a Member for many years, and worked to commercialise the organisation and stabilise the financial situation.

In 2003 he left to set up his own business, Apostles Castings Technology, a business which carries out technical and commercial consultancy around the world.

Andrew is now the Executive Secretary of the World Foundry Organization, having been the General Secretary for 20 years he is also the Clerk of the Foundry Training Trust, a charity that supports professional development for those in the casting and foundry industry.

Andrew has recently set up a new company specializing in the recycling of plastic waste which has huge synergistic benefits for the foundry sector as a user of waste sand and extraction dust.

Keynote: Situation and Challenges 

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This keynote presentation provides an overview of global casting production trends, with a particular focus on the world's five largest producers and their influence on the international foundry industry.

Drawing on current production data and industry developments, this presentation examines the factors shaping global casting demand, manufacturing competitiveness, and future industry growth, while also considering the key challenges facing the industry against an increasingly complex geopolitical landscape.

As the foundry sector continues to adapt to these changing conditions, this presentation offers valuable insights into the opportunities and risks ahead, providing attendees with a broader understanding of the trends and forces that will shape the future of the global casting industry.

 

 

Matt Schimke, Robert Bosch Australia

With more than a decade of experience at Bosch Power Tools, Matt Schimke is the Key User Manager for QLD & Export, leading strategic end-user engagement, business development and customer conversion initiatives across Queensland and international export markets. Throughout his Bosch career, Matt has built a strong reputation for delivering sustainable growth, developing high-performing teams and creating value through solution-based selling, strategic account management and commercial leadership.
Matt is recognised for his ability to identify growth opportunities, build strong customer partnerships and convert complex business challenges into practical commercial outcomes. Working across the construction, infrastructure, mining, manufacturing, logistics and industrial sectors, he has successfully led large-scale end-user conversion projects, secured strategic national accounts and delivered profitable growth through a customer-centric approach.
Today, Matt leads a team of Solution Specialists, coaching and developing capability while driving strategy execution across Queensland and export markets. Known for his commercial acumen, analytical mindset and ability to build trusted relationships, he is passionate about helping customers improve productivity, enhance safety outcomes and unlock long-term business value.
Matt welcomes connections with professionals across manufacturing, mining and industrial sectors. Whether discussing industry trends, business growth opportunities, workplace innovation or strategic partnerships, he values building meaningful relationships that create lasting impact and mutual success.
 
Bosch Power Tools - High frequency solutions
 
 
With the decline in High Frequency Tool (HFT) brands in the market, Bosch continues to support this critical industrial tool category for the Australian foundry industry. Designed specifically for demanding grinding applications, Bosch High Frequency Tools provide a proven solution for operations that require exceptional durability, continuous-duty performance and low maintenance costs. Bosch remains committed to supplying and supporting this specialist technology for foundries, metal fabrication facilities, heavy manufacturing operations and industrial maintenance environments across Australia.

Bosch High Frequency Tools utilise advanced three-phase high-frequency motor technology that delivers exceptional power while maintaining a lightweight and ergonomic design. Unlike conventional electric power tools, these systems operate via a dedicated high-frequency converter, typically at 200 Hz or 300 Hz. This increased frequency enables significantly higher motor speeds, improved efficiency and an industry-leading power-to-weight ratio, making them ideal for continuous industrial use. Bosch identifies 200 Hz to 300 Hz as the optimal operating range for achieving maximum power output with minimum motor weight.

A major advantage of Bosch High Frequency Tools is their ability to maintain near-constant speed under load. Speed reduction is limited to just 3-5% at rated load, ensuring consistent grinding performance, extended accessory life and improved productivity. The robust three-phase motor design incorporates low-vibration operation, direct cooling and dust protection technology, resulting in outstanding reliability and long service life, even in harsh foundry environments. Bosch high-frequency motors can deliver peak power of up to 2.5 times rated power for short-duration overloads while achieving up to 400 watts of continuous power per kilogram of machine weight.

Overall, Bosch High Frequency Tools deliver a unique combination of power, reliability, safety and efficiency, making them one of the few remaining premium HFT solutions available to Australia's foundry and heavy industrial sectors.
 

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Sundresh Dhanaraj, Castings Tasmania  

Sundaresan Dhanaraj is a Metallurgist and Technical Manager at Castings Tasmania Pty Ltd with over 20 years of experience in iron and steel casting technologies. He has extensive expertise in melting, refining, heat treatment, welding, and metallurgical quality control, with a strong focus on problem-solving and process optimisation.

Previously, he spent nearly 14 years at Caterpillar India, where he led R&D initiatives, developed material specifications, and optimised heat treatment and casting processes across global operations. He also served as a Caterpillar-certified auditor, evaluating more than 150 foundry suppliers worldwide.

Sundaresan is passionate about applying digital technologies, optimisation methods, and data-driven approaches to improve foundry efficiency, reduce cost, and enhance product quality. His work bridges practical metallurgy with modern innovations such as AI and process optimisation.

Intelomelt: A smart foundry platform for autonomous charge optimisation
 
 
Induction furnaces often rely on manual or spreadsheet-based charge calculations, leading to variability in chemistry control, inefficient alloy use, and costly remelts. This study presents Intelomelt, a smart charge optimisation platform that integrates linear programming (LP) and AI-driven metallurgical assistance to improve melting efficiency and consistency.

The system optimises charge composition using available scrap, returns, and alloy inventories while meeting multi-element chemistry constraints and grade-specific requirements. A spectro-based trim correction module calculates the most cost-effective alloy additions to achieve target chemistry, reducing operator dependency and decision variability. Additionally, an embedded AI assistant provides real-time guidance for heat analysis, optimisation strategies, and process decisions.

By digitising the furnace workflow and enabling data-driven decision-making, the platform improves repeatability and process control. Industrial applications indicate measurable reductions in off-chemistry heat, alloy consumption, and overall melting costs, demonstrating the potential of digital technologies to enhance productivity and sustainability in modern foundries.
 

 

Matthew Dunford, White Industries

Matthew Dunford is a Casting Simulation Specialist at White Industries. 

White Industries’ 3D printing journey

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Jan Eilers, Magma Engineering Asia-Pacific 

With over 16 years of dedication, Jan Eilers currently leads operations for the SEA and ANZ regions for MAGMA. Combining strategic business acumen with technical domain knowledge, Jan frequently presents on advanced metal casting simulation topics at conferences across Asia. He is dedicated to advancing the region's foundry industry through digital transformation, leveraging MAGMASOFT® to help manufacturers optimize their metal casting processes. Together with his regional team, Jan helps customers achieve sustainable profitability and metal casting excellence.
 

Digital casting process development – optimizing quality and economics of a rear axle shaft housing

 
 
This presentation demonstrates how metal casting simulation supports the development and optimization of a rear axle shaft housing for a tractor, courtesy of Bundy Tradores, Brazil. Starting from initial casting layout and gating concept, MAGMASOFT® simulation results are used to identify critical areas and guide the development of an optimized dual-cavity layout. The different concepts are then compared in terms of casting quality, production economics and CO₂ emissions, demonstrating how simulation-driven development can help identify the most efficient manufacturing solution.
 

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Glen Thiele, Spectrosource

Glen Thiele has been a director at Spectrosource Pty Ltd since 2014 and is responsible for sales and servicing of Belec Spektrometrie Opto-Elektronik GmbH arc/spark Optical emission spectrometers in Australia and New Zealand. Belec Spektrometrie Opto-Elektronik GmbH has been developing and manufacturing arc/spark Optical emission spectrometers for metal analysis since 1986.
Glen has a HD in Electronic Engineering from CPUT, a BCom from UNISA, a MPM and MBA from University of Wollongong.
Glen is the current Treasurer of the Australian Foundry Institute, NSW branch.
 

Traceability of spectrometer chemical analysis

 
Traceability in spectrometer chemical analysis ensures test results link to international standards through an unbroken chain of comparisons. This process relies on certified reference materials, documented calibration steps, and clear measurement uncertainties.

Core Components of Traceability

• Reference Standards: Use certified reference materials matching your sample matrix to calibrate the spectrometer.
• Unbroken Chain: Connect every measurement step from the local lab device back to SI units or primary national standards.
• Instrument Calibration: Calibrate wavelengths, detectors, and response linearity regularly using verified physical or chemical parameters.
• Uncertainty Evaluation: Calculate combined uncertainties for sample preparation, instrument drift, and data conversion.

This presentation presentation will explain traceability principles in terms of Spark Optical emission spectrometers using practical methods of achieving satisfactory results.
 

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Mickaël Dernoncourt, Metcast Services

Mickaël Dernoncourt is originally from France and moved to New Zealand in 2014 after completing a Master’s degree in Mechanical Engineering, specialising in Foundry Engineering. He brings more than a decade of New Zealand experience across foundry engineering, metal casting, and manufacturing, with expertise in casting process design, simulation, product development, and technical sales.

In his role with Metcast, Mickaël works closely with customers across the foundry, engineering, and manufacturing sectors. He provides practical technical solutions spanning melting and refractory products, additive manufacturing consumables, and process optimisation. Combining strong engineering knowledge with a commercial focus, he helps manufacturers improve quality, productivity, and profitability through value-driven solutions. He is also passionate about innovation, AI-driven business automation, and identifying opportunities to strengthen New Zealand’s manufacturing industry.

Using advanced manufacturing to recreate a classic engine block

 
 
Advanced manufacturing technologies are creating new opportunities for foundries to produce complex, low-volume and legacy components without the significant investment traditionally required for patterns and core tooling.This presentation follows the engineering journey undertaken to manufacture an engine block using 3D printed sand moulds and cores. The project began with the development of the 3D CAD model, followed by design modifications to optimise the component for casting and additive manufacturing. The casting method was then developed using traditional foundry principles combined with modern digital tools, including gating and feeding design, methoding and casting simulation. Simulation played an important role throughout the development process, allowing metal flow and solidification behaviour to be evaluated, potential defects to be identified, and design modifications to be assessed before committing to production. The final mould and core package was then manufactured using 3D sand printing, providing a direct route from digital design to the foundry floor without conventional tooling. Through this case study, Metcast will demonstrate how the combination of practical foundry expertise, 3D design, casting simulation and additive manufacturing can provide innovative solutions for complex prototypes, legacy components and low-volume castings. Ultimately, while 3D sand printing removes many of the traditional limitations of patternmaking, successful castings still rely on good foundry engineering.

 

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Clive Moore, M2H

My career started many years ago as a Patternmaker, within the Australian Automotive supply industry, using this opportunity and further education, I worked within and for Manufacturing organisations in Australia and also overseas including the management of three automotive component foundries in Australia and overseas.
My manufacturing/engineering management career experiences have also provided further opportunities, including employment with ABB and also Siemens, advising clients on using technology and developing business strategies to improve manufacturing reliability.
 

Reliability and resilience in the metal casting industry

 
Topic Reliability and Resilience in the metal casting Industry. The Australia metal casting industry is an essential manufacturer and important /critical supplier to many other industries in Australia. From the Commonwealth Governments perspective, Metal Casting is regarded as a Sovereign Industry, especially for local defence manufacturing purposes. Both Federal and all State governments have departments that are involved in supporting Australian manufacturing, to provide employment opportunities and to be able to be a local supplier of products, for the Australian markets.

However, like all manufacturers in Australia, there is constant pressure from clients, as to on time delivery at the required quality and at a competitive cost! Many Australian manufacturing and overseas companies, have adopted manufacturing improvement strategies and Software including A.I that are focused on the actual plant Reliability and the Operational Equipment Effectiveness, this is an area of potential opportunity for the Australian Metal Casting Industry. The use of purpose designed technology also extends into improving energy management and also can assist OHS&E outcomes, with the potential to provide a level of Resilience to meet enforced changes from external parties such as the EPA , also insurance companies have a vested interest in the risk management strategies deployed by companies and importantly the owner/ shareholders need to have an ROI.
 

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Lawrence Mashavave, Metso Australia

Lawrence Mashavave was born on 28 February 1967 in Kwekwe, Zimbabwe. After completing his education, he began a Foundry Apprenticeship with W.S. Craster Pvt Ltd in 1989 before starting his career with ZISCO Steel where he gained valuable experience in the foundry and steel manufacturing industry.
In 2006, he moved to South Africa, where he worked for Scaw Metals in Benoni until 2008. He then relocated to Australia and joined Weir Minerals Australia, where he spent 13 years before joining Metso Australia in 2021, where he continues to work today.
Alongside his technical career, he also studied Marketing and Communication, enhancing his ability to engage with customers, colleagues, and industry stakeholders. With more than 30 years of experience in the foundry industry, he is passionate about encouraging the next generation to pursue careers in foundries while promoting modern technology and environmentally sustainable manufacturing practices. The installation of the adiabatic cooling system has delivered operational, environmental, and financial benefits compared with the previous cooling towers.


Chris Buck, Inductotherm Group Australia 

Chris is the National Sales Manager for Inductotherm Group Australia. 

 

Benefits of Adiabatic Cooling System

 
Key Benefits

• The electric motor no longer needs to operate continuously (24 hours a day, 7 days/week), as was previously required to manage Legionella risks. The system now operates only when needed, as the fans are not required to run continuously.
• Water consumption has been reduced by approximately 95% due to the significantly lower cooling water demand. A water savings of approx. 800kL/month
• Chemical treatment and servicing costs have been eliminated. Previously, these expenses averaged approximately $3000.00 per month.
• Routine maintenance associated with chemical dosing equipment has been eliminated, reducing both maintenance costs and production downtime.
• The system has an estimated payback period of approximately 18 months, with substantial ongoing savings from reduced chemical purchases, water testing, maintenance, and operating costs.
• Both the furnace and the shakeout heat exchanger are now cooled using the four-fan adiabatic cooler, replacing the previous cooling towers that required ongoing chemical treatment and maintenance.
• Operating noise is very low, while chemical costs have been virtually eliminated.
• The addition of spray cooling Water is only used during extremely hot summer conditions when the adiabatic spray system is activated, resulting in negligible overall water consumption.
• The system has fewer moving parts, making it simpler, more reliable, and easier to maintain.
 
Issues Eliminated

The new system has removed several ongoing operational concerns, including:
• Council permitting requirements and inspections.
• Legionella management risks.
• Chemical treatment and dosing equipment maintenance.
• Cleaning and maintenance of cooling tower water basins.
 
Overall Performance

The adiabatic cooling system has proven to be an excellent solution for foundry induction furnace cooling. It offers outstanding cost effectiveness, environmental benefits, operational simplicity, and reduced maintenance requirements.
Since commissioning, no operational problems have been encountered. The only unexpected outcome has been the system's exceptional efficiency.
Although it is still too early to accurately quantify annual savings, they are expected to be significant. Based on current performance, the installed cost has proven to be well justified, with an anticipated payback period of approximately 18 months.
 

 

Andy Pickering

  

Andy Pickering, Omega Sinto Foundry Machinery 

Andy Pickering is a highly respected foundry professional with more than 40 years’ experience across technical, commercial and leadership roles in the global foundry industry. Currently serving as Sales Director at Omega Sinto Foundry Machinery Ltd, Andy leads commercial activities across the Middle East, Indian Sub-Continent and Southeast Asia.

Andy began his career in the UK as a foundry technologist, working across iron, steel and aluminium foundries including Charlestown Engineering, Cronite Castings and Cosworth Castings. In 1987, he joined Hepworth Minerals and Chemicals as a Technical Service Representative, providing nationwide support across silica sands, binder systems, refractory coatings and moulding ancillaries.

In 1990, Andy joined Borden Chemical, where he spent 23 years in senior technical and commercial roles, supporting key customers across Europe, the Middle East and India. His expertise includes chemical bonded sand systems, alkaline phenolic binder development, mould handling and sand reclamation practices.

Keynote: 40 years in the Foundry industry - what lies ahead? 

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Join Andy Pickering for this keynote presentation as he reflects on more than 40 years of experience in the foundry industry, exploring how the sector has evolved, the challenges that lie ahead, and the implications for the Australian foundry industry. As global casting demand continues to grow, Andy examines the factors driving this expansion and considers its impact on future casting capacity worldwide.

To meet this growing demand, three critical areas are explored: people, power, and process.

People – The industry faces an acute shortage of skilled and specialised workers. Andy discusses how the sector can attract new talent, retain experienced personnel, and develop the next generation of industry leaders.

Power – Rising energy costs are having a profound impact on the casting industry. Energy has become a major driver of operational expenses, forcing structural changes in production methods and accelerating the adoption of energy-efficient technologies.

Process – The need for innovation is driving change across all areas of the industry. Key developments include advanced organic chemical binders and the transition to inorganic binders, reducing costs and improving environmental performance. Other innovations include the increasing use of artificial sand as a high-performance alternative to natural silica sand, advanced recycling technologies for spent foundry sand, and the integration of automation, advanced machinery, and artificial intelligence to improve efficiency, safety, and quality.

The global foundry industry is undergoing a profound transformation, driven by technological innovation and the continued evolution of metal casting processes. While geopolitical tensions and regional shifts in production present ongoing challenges, the industry remains on a steady growth trajectory. This keynote provides valuable insights into the opportunities and challenges that will shape the future of foundries in Australia and around the world.

Sand reclamation techniques exploring our options to minimize waste and save energy

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Primary reclamation of foundry sand is now commonplace, both nationally and globally. This presentation considers how we can further improve reclamation process and techniques while considering the impact on pollution control, energy saving and cost reduction.
Firstly we consider how to effectively control and gain maximum benefit from our existing primary reclamation system, and the influence of loss on ignition when using organic binders. Having optimized primary reclamation what options do foundries have for further increases in sand reclamation level.
Thermal processing is a well-known method for reducing sand waste. We consider the current influence of thermal processing, the advantages and disadvantages and the potential energy savings associated with heat recovery.
As an alternative to thermal reclamation, secondary attrition is discussed. By employing the latest techniques significant increases in reclamation level can be achieved while also improving the sand grain angularity. The potential cost reduction and technical benefits associated with this method are discussed for a variety of different foundry binder systems and process. 

 

  

Peter Grandy, Bluescope Steel 

Peter Gandy has worked in the Steel Industry for 40 years, in Australia, the US, Europe, and throughout Asia,primarily in Rolling Mills and hot forming. Peter has worked in local casting operations at Loadarm in Kurnell and is currently a Process Specialist at Bluescope Innovation labs Port Kembla developing the next generation of galvanised coatings.

The installation and optimisation of an Induction Furnace Casting system in the development of next generation metal coatings at Bluescope Innovation Laboratories

 
A key corporate objective for Bluescope is to develop and maintain market leadership in coated steel products. As such, Bluescope’s Innovation Labs have been tasked to optimise product simulation capabilities in the development of Next Gen Metal Coatings. In 2025 a programme began to upgrade the Hot Dip Process Simulator lab to include a combined Induction Furnace/Caster to supply experimental melts for the production of test panels via the Hot Dip Process simulator (Metal coating pilot line). This paper outlines the resultant process efficiencies, product development benefits, and energy savings generated by the introduction of the induction furnace caster.
 

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Charlie Anderson, Monocure3D

Charlie Anderson is the Founding Director of Monocure3D, an Australian manufacturer of UV-cured resins for 3D printing, with a strong focus on dental, engineering and industrial applications. With a background in television production spanning over 20 years, Charlie transitioned into the family business, bringing a practical, problem-solving approach to product development and industry engagement.

He now leads research and development, working closely with chemists and production teams to formulate advanced materials and deliver real-world solutions for additive manufacturing. Under his direction, Monocure3D has expanded into industrial-scale applications, including large format resin 3D printing systems for foundry and casting use.

Charlie regularly collaborates with industry partners, resellers and end users to refine materials and workflows, ensuring they meet the demands of modern manufacturing environments. He has previously presented on resin 3D printing technologies and is focused on helping industries adopt practical, efficient alternatives to traditional processes.


The foundry industry is facing an increasing shortage of skilled patternmakers, creating pressure on production timelines, costs, and capacity. This presentation explores how large format resin 3D printing is emerging as a practical and scalable alternative to traditional patternmaking.

 

Large format resin 3D printing for foundry pattern production

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Over the past few years, the cost of industrial resin 3D printing systems has reduced significantly. Equipment that was previously in the range of $500,000 is now available closer to $50,000, while offering improved reliability, accuracy, and surface quality. This shift is making the technology far more accessible to foundries of all sizes.

Modern systems are now capable of producing very large components, with build volumes reaching up to 1700×850×650 mm, allowing full patterns to be manufactured in a single build. In addition, DLP-based systems are available for smaller components, including configurations with automatic part removal to support higher throughput production.

The presentation will cover how these technologies integrate into foundry workflows, including pattern production, material performance, dimensional accuracy, and practical considerations for implementation. It will also highlight how locally developed resin materials can be tailored for specific casting applications.

Monocure3D, as an Australian manufacturer of photopolymer resins, has been working closely with an overseas printer manufacturer to develop systems and materials suited to local industry requirements. This includes customised resins, technical support, and implementation guidance to ensure successful adoption.

The session will provide a clear and practical overview of how resin 3D printing can support the foundry sector as it adapts to ongoing workforce and production challenges.

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Andrew Johnstone, Dickinson’s Metallurgical Supplies

Andrew Johnstone is the General Manager of Dickinson’s Metallurgical Supplies, one of Australia’s leading suppliers to the foundry and the wider metallurgical industries.
Beginning his career in hands-on operational roles, Andrew developed a practical understanding of production, logistics, alloy processing, packaging, and customer supply requirements from the ground up.

Commodity metal pricing and supply trends

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Today, Andrew brings nearly three decades of industry experience to leading Dickinson’s strategic direction across sourcing, commodity risk, international supplier partnerships, and market development. Known for his practical approach and strong industry relationships, Andrew combines operational expertise with commercial acumen to help drive long-term growth and innovation.
Outside of work, Andrew has a passion for fishing, exploring remote Australia, technology, and the outdoors. An overview of current global commodity metal and ferro alloy market trends, including pricing volatility, supply chain pressures, and the key factors influencing raw material availability for the foundry industry.

 

Alan Cooke, AFI National Vice President

33 years of working at Ford Motor Company, ended in December 2016. Through this period I was fortunate to develop a level of manufacturing know-how covering Quality Systems, Product Development, People Management, Lean Manufacturing Principles, Supplier Quality Development and Metal Casting Processes (Greensand Moulding, Coldbox Coremaking, Al and Fe Casting, Induction Melting) in a high volume manufacturing environment.

Industry update

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Through my early years at Ford, I completed a Metallurgy qualification at RMIT, Melbourne. Since finishing at Ford, I’ve been able to apply my manufacturing knowledge in the building industry working a casual, part time role at Stegbar.Now in semi-retirement I enjoy Family, Footy, Rogaining, StreetO, Running, Community Choir and being involved in the Australian Foundry Institute.

 

Brett Lawrence, AFI National President 

Brett began his career in the foundry industry June 1985 at an aluminium diecasting plant in Sydney (Lawrenson Diecasting). At Lawrenson’s I held positions in all areas of Administration (including product costing, accounts payable / receivable, human resources and management information systems). I transferred as Financial Controller to our Adelaide iron foundry in 1997 which was subsequently replaced in 1998 with a greenfield site which doubled the output capacity.

Metal Casting Australia + AGM

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Following the 2006 installation of an additional furnace and the largest vertical moulding line in Australia I became General Manager of the site. Our foundry has a capacity of 45,000 MT sold p.a. with up to 60% of our output exported, primarily for the rail infrastructure marketMy qualifications include Associate Diploma of Business - major in Accounting, Graduate Diploma in Business Management (Executive).

 

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