Foundry Talk

Join hosts Perry Merritt and Nate McLain on the Foundry Talk podcast for a lively conversation with Jim Gauldin, President of Palmer Manufacturing. Jim traces Palmer’s roots back to a small evening foundry run by Jack Palmer and his father, where building their own sand mixer for speed led to an unexpected sale that sparked a full equipment-manufacturing business.
The discussion highlights Palmer’s innovative Flip Mold Machine (FMM), a compact all-in-one rollover/carousel design that boosts production cadence, saves floor space, and reduces operator fatigue—with growing installations and strong customer feedback.
They explore Palmer’s diversification into rail traction sand systems, golf course sand reclamation, and more. The conversation dives into Foundry 4.0—predictive sensors, data connectivity, AI possibilities, cybersecurity concerns, and the real challenges of adoption in small-to-large foundries.
Heartfelt stories celebrate the larger-than-life Jack Palmer—his creativity (including casting his own face in aluminum), boundless energy, and enduring legacy.
A great listen for anyone in metal casting interested in practical innovation, equipment evolution, and the future of the industry.
Listen now and visit https://palmermfg.com/ for videos, equipment details, and Simple Solutions That Work magazine. #podcast #foundry #manufacturing #smallbusiness

Nate frequently says foundry people are "the salt of the earth," and this episode's guest certainly fits the bill. Join us as we sit down with Rick Buellesfeld, owner and operator of Sooner State Pattern Works in Blackwell, Oklahoma. Rick shares the story of founding his pattern-making business on New Year's Day 1989 after purchasing a shop, growing it from a small team to a dedicated crew of about eight, including family members like his son Randy (shop manager) and daughter Gayle (office manager). He reflects on the evolution from traditional manual layout work to embracing CNC machining since the early 1990s, tackling complex patterns for sand casting, investment casting, hydraulic components, impellers, diffusers, and even plastic injection molds. The conversation covers industry challenges like shrink variations, foundry-specific rigging, foreign competition, employee ideas and retention, the value of quality control, and the pride in building durable, precise tools that foundries and end-users rely on—delivering insights into the heart of American pattern-making and metal casting. #podcast #foundry #manufacturing #smallbusiness#podcast #foundry #manufacturing #smallbusiness

In this episode of Foundry Talk, hosts Nate McClain and Perry Merritt chat with Dave Schmidt, VP of Finite Solutions Incorporated, about metal casting simulation software. Dave shares the company's history since 1985, debunking misconceptions (yes, it works!), and demos flow/solidification analysis to predict defects, optimize rigging, and improve yields.
They explore real-world examples like turbulent fills, bottom gating issues, and how simulation aids robust processes—essential for modern foundries. Tips on using tools like SOLIDCast, plus contract services for those without in-house expertise.
Contact: dave@finitesolutions.com or (262) 644-0785. Visit finitesolutions.com for more. #podcast #foundry #manufacturing #smallbusiness

In this episode of Foundry Talk, hosts Nate McClain and Perry Merritt talk with Bill Crouse of ProTech Pattern in rural Wisconsin. Bill shares his path from freelancing in 1996 to opening his dream shop in 2018—built right next to his home for ultimate convenience (and occasional work-home blur).
They discuss running a small, fast-response pattern shop: long hours, quick turnarounds, CNC machining, laser scanning for quality, and exploring 3D printing for gating and cores. Bill covers the shift from traditional bench work to modern CAD and additive tech, plus the value of self-taught problem-solvers.
Full of practical tips and passion from a dedicated small-shop operator—perfect for foundry folks and patternmaking enthusiasts. #podcast #foundry #manufacturing #smallbusiness

The Foundry Talk Podcast is back for a brand new season. Join us Monday February 9th as we start talking to new guests.