Advancing Foundry Training Through Virtual Reality: A Low-Cost, Immersive Learning Environment

Abstract

Metal casting foundries present hazardous working conditions, making traditional training methods costly, time-consuming, and potentially unsafe. To address these challenges, this study presents a Virtual Reality (VR) training framework developed for the Tennessee Tech University (TTU) Foundry. The objective is to enhance introductory training and safety education by providing an immersive, interactive, and risk-free environment where trainees can familiarize themselves with safety protocols, equipment handling, process workflows, and machine arrangements before engaging with real-world operations. The VR foundry environment is designed using Unreal Engine, a freely available software tool, to create a high-fidelity, interactive simulation of metal casting processes. This system enables real-time user interaction, scenario-based training, and procedural guidance, ensuring an engaging and effective learning experience. Preliminary findings and prior research indicate that VR-based training enhances learning retention, improves hazard recognition, and reduces training time compared to traditional methods. While challenges such as haptic feedback limitations and initial setup costs exist, VR’s potential in engineering education and industrial training is substantial. This work-in-progress study highlights the transformative role of VR in foundry training, contributing to the development of a safer, more efficient, and scalable workforce in the metal casting industry.

1. Introduction

Establishing a real manufacturing environment is a lengthy and resource-intensive process, requiring careful consideration of design, cost, and operational factors. However, advancements in VR and Digital Twin technologies have revolutionized how such environments are conceived, tested, and optimized. Several powerful software tools now enable designers and practitioners to construct highly detailed and interactive virtual representations of manufacturing setups, allowing for real-time simulation, validation, and optimization before any physical implementation [1].

VR technology provides immersive, first-person experiences that allow engineers to explore, interact with, and refine manufacturing environments in a risk-free digital space. This capability enhances design validation, operator training, ergonomic assessments, and process optimization, significantly reducing errors, costs, and downtime [2]. Moreover, Digital Twins—dynamic, real-time digital replicas of physical assets—go beyond static models by integrating Internet of Things (IoT), Artificial Intelligence (AI), and simulation data to provide continuous feedback and predictive insights [3]. These virtual counterparts enable real-time monitoring, predictive maintenance, and performance analytics, allowing organizations to refine workflows, troubleshoot inefficiencies, and make data-driven decisions before committing to physical changes.

Manufacturers can significantly accelerate development cycles, minimize costs, and enhance operational efficiency by leveraging VR for immersive visualization and Digital Twins for real-time data-driven insights [4]. These technologies are rapidly becoming essential in Industry 4.0, bridging the gap between conceptualization and real-world implementation with unprecedented precision and adaptability [5,6].

This study presents an innovative VR framework developed for the metal casting process in which molten metal is poured into a mold to produce a desired shape after it solidifies [7]. The primary objective of this work-in-progress initiative is to leverage VR technology to enhance introductory training and safety education in foundry operations. The virtual foundry environment aims to provide a risk-free, immersive learning platform where users can gain hands-on experience with safety protocols, equipment usage, process workflows, and machine arrangements before engaging with a real-world foundry. Developed using Unreal Engine, a widely adopted and freely available software tool, this VR environment offers an interactive and scalable solution to traditional training challenges in metal casting [8].

VR has emerged as a transformative tool in industrial training, particularly for hazardous and high-risk environments such as metal foundries. By providing a safe, cost-effective, and highly immersive alternative to conventional training methods, VR enables learners to visualize complex processes, practice critical tasks, and develop procedural familiarity without the dangers of molten metal, high temperatures, and heavy machinery [9]. This study explores the effectiveness of VR in foundry training, assessing its potential to improve learning outcomes, safety awareness, and workforce preparedness.

Prior research underscores the efficacy and benefits of VR in photogrammetry and prototyping [10,11]. Gavish et al. demonstrated that VR and Augmented Reality (AR) significantly improve learning efficiency and error reduction in industrial maintenance and assembly tasks [12]. Although VR-based training may initially require longer durations than traditional methods, it offers greater retention and proficiency—key advantages for foundry training, where precision and safety are paramount. Overall, VR enhances industrial training by combining immersive simulation with risk-free experiential learning, improving safety and retention outcomes.

The application of VR in large-scale industries further validates its effectiveness. For instance, Boeing’s VR-based aircraft maintenance training program reduced training time by 75% while maintaining or improving task accuracy [13]. Such findings suggest that VR-driven foundry training could enhance skill acquisition and process familiarity, allowing trainees to practice metal casting techniques and equipment handling in a controlled, interactive environment before transitioning to real-world operations.

In the context of engineering education, VR’s ability to simulate realistic technical processes and enhance learner engagement has been widely recognized. Soliman et al. found that VR improves conceptual understanding and remote accessibility, making it particularly relevant for foundry training, where metallurgical principles and hazardous equipment handling require high levels of comprehension and practice [14].

Moreover, VR has proven an effective safety training tool [15]. A systematic review by Scorgie et al. found that VR-based safety modules significantly improve knowledge retention and hazard recognition compared to traditional training methods [16]. Given the inherently dangerous nature of foundries—with risks including molten metal exposure, toxic fumes, and heavy machinery operation—VR offers an essential platform for reinforcing safety protocols in a fully immersive yet risk-free environment.

Recent research in VR training has demonstrated the effectiveness of immersive learning environments in improving procedural knowledge and situational awareness, particularly in high-risk fields such as firefighting, construction safety, and aerospace maintenance [17,18]. However, few studies have focused on the application of VR in the context of metal casting—a process that involves unique hazards, specialized equipment, and complex workflows requiring domain-specific procedural training. Existing VR platforms in manufacturing tend to emphasize assembly line simulations or general safety protocols, lacking the process fidelity and contextual realism needed for foundry-specific education [19].

Furthermore, prior studies that have implemented VR for industrial training often rely on abstracted simulations or generic environments, without detailed modeling of the casting process, spatial layout, or operational interdependencies critical to foundry operations [20,21]. This study addresses this gap by developing a VR training system specifically for metal casting foundry education, integrating interactive task sequences, equipment-specific procedures, and simulated hazards in a risk-free, immersive environment. By focusing on this niche yet vital domain, our work extends the capabilities of VR-based industrial training into areas previously underserved by both commercial and academic tools.

Despite its numerous advantages, VR training faces several challenges. High initial costs, the need for realistic haptic feedback, and potential user discomfort (e.g., motion sickness) can hinder widespread adoption. Additionally, while VR excels in cognitive learning and procedural training, it must be supplemented with hands-on experience to ensure full practical competency. By addressing these concerns, developing a VR foundry training system can maximize its effectiveness, bridging the gap between theoretical learning and hands-on foundry operations.

While several advanced features—such as haptic feedback, collaborative multi-user scenarios, real-time Personal Protective Equipment (PPE) compliance monitoring, and automated assessment—are part of the long-term development roadmap, the present version of the system includes a fully functional VR simulation environment with scenario-based training, interactive task sequences, and embedded safety information modules. These core components were the focus of the current pilot study and form the basis of the reported findings.

This study is guided by the following research question: To what extent does a VR-based foundry training system improve safety knowledge, hazard recognition, and procedural understanding among undergraduate engineering students compared to traditional instructional methods? We hypothesize that students trained using the VR system will demonstrate higher gains in (1) safety knowledge retention, (2) hazard identification accuracy, and (3) procedural task confidence. To evaluate this, we implemented a pilot study using a pre/post-test design and collected both quantitative and qualitative data from participants in a university-level manufacturing course.

While the development of this VR training system was informed by prior research indicating the pedagogical benefits of immersive simulation (e.g., increased engagement, improved safety awareness, and enhanced skill acquisition), this particular study focuses on the design and implementation stages rather than on empirical validation. The primary contribution of this paper is the development of a functional, domain-specific VR environment tailored for metal casting education, which will serve as the foundation for future assessment studies.

This paper presents the current progress and ongoing developments of the VR foundry training system at TTU. Through this initiative, the authors aim to demonstrate VR’s potential to revolutionize metal casting training, providing a scalable, immersive, and data-driven approach to enhancing the foundry industry’s safety, efficiency, and workforce readiness. Initially, the paper presents the components of a metal casting foundry, and the Virtual Foundry System design is debriefed. The development environment is presented in a tabulated format so that the readers can grasp the infrastructure of each component. Finally, the educational impact of the study is presented, including a beta testing study from a foundry class environment.

2. Materials and Methods

This section outlines the technologies used to develop and implement a virtual foundry simulation designed to replicate real-world foundry processes. The VR system aims to provide an immersive training environment that mimics the key operational aspects of a physical foundry, including furnace operations, crucible handling, mold preparation, and post-processing. By integrating innovative VR, the simulation ensures that the training experience closely aligns with actual foundry practices. This portion details the components of the virtual foundry, highlighting the system’s design, functionality, and how it can be used to enhance training outcomes for metal casting techniques while maintaining a safe and effective learning environment.

The scope of this study is limited to evaluating the impact of the currently implemented VR training features. The experimental design, assessments, and results discussed in this paper are based solely on the core modules that were completed and tested, including furnace operations, mold preparation, safety signage navigation, and hazard identification exercises. Features such as haptic integration and team-based interactivity are part of planned future iterations and are not included in the present evaluation. As such, our findings should be interpreted as a pilot validation of the system’s foundational components rather than a full-scale summative assessment.

The virtual foundry seen in Figure 1 is designed to replicate real-world foundry processes as accurately as possible while operating within technological constraints. Regular site visits to the TTU foundry provide essential insights to ensure precise process replication. To create an immersive and effective training environment, the VR simulation incorporates key aspects of real foundry operations, including furnace operations, crucible handling, mold preparation, casting, and post-processing.

2.1. Furnace Operations

The virtual furnaces are designed to closely resemble their real-life counterparts in both appearance and function, ensuring that VR-based training translates effectively to real-world foundry work. TTU’s foundry houses aluminum, iron, and non-ferrous furnaces, each requiring different handling techniques:

• The aluminum furnace requires the use of a ladle for transporting molten metal.
• The iron and non-ferrous furnaces, still in development, will utilize a winch system to pour metal into a heated crucible.

To ensure usability, the VR furnace control system is simplified while maintaining key functionalities. A three-button control panel seen in Figure 2 allows incremental temperature adjustments, displaying the current furnace temperature and heating status. While real-world control panels vary depending on model and power supply, the virtual foundry replicates essential features common to industrial furnaces.

2.2. Crucible Handling

In real foundry work, crucible handling typically requires two operators for safe and coordinated material transfer. To simulate this in VR, our current development features a robotic assistant that mirrors the trainee’s actions, serving as a virtual partner during the pouring process; however, this feature is still under development and has not yet been fully implemented in the live system. This approach helps users develop a foundational understanding of crucible handling mechanics and coordination. While the communication aspects of team-based work are not yet integrated, future versions of the system will support multi-user VR functionality, enabling two participants to interact within the same virtual environment, perform coordinated tasks, and engage in verbal or gesture-based communication. This enhancement aims to better replicate real-world collaboration and reinforce safe team-based handling practices. To further enhance realism, the virtual crucible (Figure 3) glows when heated to approximately 700 °C, simulating the thermal behavior observed in actual foundry settings.

2.3. Mold Preparation

The mold preparation process is among the most complex to replicate in VR. In a real foundry, this process involves multiple steps, including adding, packing, and compacting casting sand around a pattern. Due to accuracy limitations in measuring user input, additional hands-on training may be necessary to supplement VR-based learning.

Nevertheless, the VR simulation will preserve key elements of the real-world process by incorporating molding frames, casting patterns, sand, and compression tools to provide an interactive and structured mold preparation experience.

2.4. Post-Processing

Once the casting process (Figure 4) is complete, post-processing is essential to refine the final product by smoothing rough edges and surfaces.

While real-world foundry work utilizes a variety of tools, the virtual foundry focuses on fundamental post-processing techniques, including:

• Grinding machines for removing imperfections.
• Polishing machines for finishing cast surfaces.

To maximize training transferability, separate grinding and polishing machines will be implemented for ferrous and non-ferrous casts, reflecting real-world material differences.

Overall, by integrating these core foundry operations into a VR environment, trainees gain a structured, interactive, and risk-free learning experience that closely aligns with real-world metal casting practices. While certain physical elements still require hands-on training, the virtual foundry serves as an effective preparatory tool for enhancing safety, efficiency, and technical competency in foundry operations.

3. Results

This section presents the design, development, and implementation details of the Virtual Foundry System, highlighting key features and mechanisms that contribute to its effectiveness as a training tool. The system integrates immersive 3D modeling, realistic physics simulations, and interactive training components to replicate real-world foundry operations in a virtual environment [22]. By utilizing Unreal Engine 5 and focusing on system optimization for standalone VR headsets, the platform delivers a high-fidelity learning experience that emphasizes safety, procedural accuracy, and user engagement. This section outlines the system’s design architecture, development process, optimization techniques, and data analytics used to evaluate its performance and user outcomes, providing a comprehensive overview of its functionality and effectiveness as a virtual training solution.

3.1. Virtual Foundry System Design

3.1.1. Immersive Scene and Equipment Simulation

The VR foundry environment features detailed 3D models of foundry equipment, optimized for standalone VR headsets such as the Meta Quest 2 and 3. The simulation incorporates real-world physics and material behavior to enhance training fidelity, including:

• Heat Transfer Models—Simulates temperature-dependent material transformations, such as metal heating, melting, and cooling.
• Heat Source (Figure 5)—Controls the temperature of other nearby objects by calling their “UpdateTemp” function, heating them over time.

• Furnace (Figure 6)—Controlled via control panel with interactive buttons, allowing the user to power on/off the furnace or adjust target temperature levels.

• Crucible (Figure 7)—Holds and heats metals, melting them at a sufficient temperature and storing the resulting molten metal for pouring into molds.

• Melting Process (Figure 8)—Processes melting of metallic objects (such as ingots) into their liquid form, which can be contained and manipulated by other objects.

• Molten Metal Behavior—Implements simplified fluid dynamics to replicate the viscosity and flow characteristics of molten metal during pouring.
• Collision Physics—Ensures realistic object interactions, preventing unnatural movements and reinforcing safety constraints.

3.1.2. Interactive Training Mechanics

The VR system integrates advanced training mechanisms to enhance user engagement and ensure procedural accuracy:

• Enforced Protective Gear Compliance—Users must equip virtual PPE before interacting with foundry materials, reinforcing safety protocols. When completed, this feature will accurately represent the safety equipment found in real metal casting foundries.
• Dynamic Hazard Warnings—The system detects unsafe actions in real time and provides immediate feedback to prevent potential hazards.
• Step-by-Step Interactive Tutorials—Guided, interactive training modules walk users through each stage of foundry operations, ensuring proper execution of procedures.

This system design not only enhances safety and procedural understanding but also provides an immersive, hands-on learning experience in a risk-free virtual environment.

3.2. Development Process

3.2.1. Software Architecture and Optimization

The Virtual Foundry System is developed using Unreal Engine 5, with ongoing porting to Unity 6 for broader platform compatibility. The software follows object-oriented programming principles, such as polymorphism and modularity (see Figure 9), ensuring scalability, maintainability, and efficient code reuse. Key optimizations include the following:

• Rendering Enhancements—Level-of-detail (LOD) adjustments and occlusion culling minimize processing overhead, improving performance on standalone VR headsets.
• Physics Simulations—Rigid-body-based physics ensures realistic object interactions while keeping hardware requirements manageable.

3.2.2. Data Analytics and Performance Evaluation

To assess the effectiveness of VR-based training, key performance metrics are continuously tracked. When automatic performance evaluations are implemented, the system will calculate the following:

• User Completion Times—Measures efficiency improvements across multiple training sessions.
• Error Rates—Logs procedural deviations and unsafe actions to evaluate learning progression and identify areas for improvement.

3.2.3. Version Control, Asset Management, and Documentation

To maintain software integrity and ensure seamless development, the project adheres to strict version control and documentation standards:

• Version Control—Managed through Git with a private GitHub repository for code tracking and collaboration.
• Asset Compliance—All 3D models, textures, and external assets adhere to licensing regulations.
• Comprehensive Documentation—Although documentation for future project expansion is not yet complete, inline code comments and external developer guides will facilitate long-term project sustainability and team collaboration.

By integrating structured software development practices, real-time analytics, and robust version control, this system ensures a scalable and data-driven approach to VR foundry training.

3.3. Research Design and Participants

A quasi-experimental study was carried out in Spring 2025 with two groups of undergraduate students taking a metal casting course at TTU. The experimental group (n = 15) engaged in VR-based safety and procedural training using the developed Unreal Engine simulation, while the control group (n = 15) received traditional classroom instruction, including slides, lectures, and video demonstrations.

3.3.1. Instruments and Data Collection

To measure learning gains, the instructor gave the same assessments before and after the training. These included a set of questions on safety protocols, a hazard identification task using image-based scenarios, and a self-assessment of confidence in performing key foundry procedures. Additionally, feedback surveys and instructional observations were used to collect qualitative insights on engagement and usability.

3.3.2. Data Analysis

Assessment scores were analyzed using paired t-tests to measure within-group improvements and independent t-tests to compare between-group outcomes. Survey responses were coded thematically to identify patterns in learner experience and perceived value of the VR training system.

Preliminary results showed that the group trained with VR had significantly higher safety test scores after the training (average score = 82.3, standard deviation = 6.4) compared to the control group (average score = 74.1, standard deviation = 7.8), with a statistically significant difference (p < 0.05). In addition, the VR group identified hazards more accurately, outperforming the control group by an average of 15%. Confidence levels were also higher among VR participants—87% reported feeling “confident” or “very confident” in performing the tasks, compared to only 53% in the control group.

4. Discussion

The development of this VR foundry training system presents a unique approach to industrial training by integrating immersive, interactive, and physics-driven simulations. Unlike conventional training methods that rely on static instructional materials or in-person demonstrations, this VR system provides a risk-free, scalable, and cost-effective alternative for introducing users to hazardous metal casting environments. This system enhances procedural understanding and safety awareness before trainees engage with actual foundry equipment by accurately simulating real-world foundry processes—such as furnace operations, crucible handling, mold preparation, casting, and post-processing.

We acknowledge that the system is in an iterative stage of development. While the current implementation has been tested for single-user training scenarios, additional components such as haptic feedback (for tactile realism), AI-driven automated feedback systems, and multi-user collaborative training modules are actively being developed. These future enhancements will allow for the deeper exploration of team dynamics, compliance training, and adaptive learning strategies. Subsequent studies will expand both the participant pool and assessment dimensions to evaluate these extended functionalities under controlled conditions.

While the initial investment in VR hardware and development can range from USD 2000 to 10,000, depending on system complexity, the long-term benefits include significant cost savings. These arise from reduced material waste during training, the lower risk of injury-related costs due to improved safety awareness, and less downtime caused by equipment misuse. Additionally, VR training allows for repeatable practice without consuming physical resources, which leads to more efficient onboarding of new personnel. As more usage data are collected, we plan to conduct a detailed cost–benefit analysis to quantify these savings and assess ROI across educational and industrial training settings.

4.1. Advantages of the VR Foundry System

One of the primary benefits of this system is its ability to improve safety in metal casting training. Traditional foundry training exposes trainees to significant hazards, including high temperatures, molten metal, and heavy machinery. VR eliminates these risks while allowing users to develop muscle memory and procedural accuracy in a controlled environment. Additionally, the cost-efficiency of VR-based training reduces material waste and minimizes the need for repeated hands-on demonstrations, ultimately lowering operational costs for training facilities.

Furthermore, this development is highly scalable and accessible. Unlike traditional training that requires physical foundry access, VR enables institutions and companies with limited resources to provide realistic foundry training remotely. This is particularly advantageous for educational institutions and small manufacturing enterprises that lack full-scale foundry facilities [23].

4.2. Barriers and Obstacles

Despite its advantages, several challenges must be addressed to maximize the effectiveness of the VR foundry system. One major barrier is the lack of haptic feedback—while VR can simulate visual and auditory cues, it does not fully replicate the tactile experience of handling molten metal, using heavy tools, or feeling heat radiating from furnaces. User adaptation is another obstacle; some trainees may experience discomfort, such as motion sickness, or require additional guidance to navigate the virtual environment effectively. Additionally, the high initial investment in VR hardware and software development can be a limitation for organizations with budget constraints, even though long-term cost savings are expected.

4.3. Uniqueness and Market Comparison

Compared to other VR-based manufacturing training applications, this VR foundry system stands out due to its focus on high-risk, heat-intensive metal casting operations, an area often overlooked in mainstream industrial VR applications. Many existing VR training solutions focus on CNC machining, welding, or assembly line processes, where interaction with hazardous materials is minimal. The integration of dynamic heat transfer models, molten metal physics, and complex interaction further distinguishes this system from general-purpose VR manufacturing training programs.

While major corporations like Boeing and Siemens have leveraged VR for maintenance and assembly training, their applications primarily emphasize precision engineering and logistics rather than hazardous material handling. In contrast, this VR foundry system directly addresses safety concerns and skill development specific to metal casting, making it a pioneering solution in virtual manufacturing training.

Overall, the current development presents a transformative shift in foundry training methodologies. By refining its features, addressing haptic limitations, and expanding accessibility, this system has the potential to revolutionize workforce training in metal casting and set a new standard for safety-focused industrial VR applications.

4.4. Theoretical Underpinnings and Pedagogical Models

The design of the VR foundry training system was grounded in Kolb’s Experiential Learning Theory (ELT) [24], which emphasizes the importance of concrete experience, reflective observation, abstract conceptualization, and active experimentation in learning. By simulating real-world scenarios in an immersive environment, the VR system allows learners to engage in hands-on exploration of foundry operations without physical risk. Additionally, principles of constructivist learning theory informed the development of the interactive modules, encouraging learners to build knowledge through discovery, contextual cues, and problem-solving tasks embedded in the virtual environment. This approach aligns with situated learning [25], in which knowledge is acquired through participation in authentic contexts, such as the virtual foundry floor, rather than passive observation [26].

4.5. Instructional Design Principles

Instructionally, the VR experience was designed following Gagné’s Nine Events of Instruction [27], incorporating attention cues, clear learning objectives, guided practice, and feedback mechanisms. Scenario-based learning elements were introduced to allow users to progress through increasingly complex safety procedures and operational tasks, simulating real-life contingencies. The system was also optimized using Cognitive Load Theory [28], aiming to reduce extraneous load by simplifying user interface interactions and providing chunked information at appropriate stages. This deliberate instructional design helps ensure that the immersive experience promotes deep learning rather than mere visual engagement [29].

4.6. Evaluation of Instructional Outcomes

Although this study is a work in progress, preliminary instructional outcomes were assessed through pilot testing with undergraduate students enrolled in the Manufacturing Processes course. Informal observations and post-session surveys indicated increased learner confidence, enhanced understanding of equipment safety protocols, and a marked improvement in hazard identification tasks compared to baseline measures. Students reported that the immersive environment helped them visualize and mentally rehearse procedures more effectively than traditional safety briefings [29]. These findings suggest that the VR-based training system holds significant promise for improving learning retention and engagement in hazardous industrial environments.

5. Conclusions

The development of the VR-based foundry training system represents a significant advancement in industrial training, offering a safe, cost-effective, and scalable solution for training in hazardous metal casting environments. By accurately simulating critical foundry processes—such as furnace operations, crucible handling, and mold preparation—this VR system allows trainees to gain practical experience in a risk-free environment, thereby improving safety, procedural accuracy, and efficiency. The incorporation of real-world physics and dynamic simulations ensures that the training experience closely mirrors actual foundry operations, fostering a deeper understanding of the complexities involved in metal casting.

While the system provides substantial benefits, challenges remain, including the need for haptic feedback to simulate tactile sensations and the adaptation of some users to the virtual environment. Additionally, addressing the high initial setup costs and enhancing the interactive aspects of teamwork in VR will be critical for broader adoption and effectiveness. However, the scalability of the system offers a promising path for organizations with limited physical foundry access to provide high-quality training remotely, paving the way for more inclusive and accessible industrial education.

Future work will focus on refining the system’s capabilities by incorporating advanced haptic feedback technologies, which will enhance realism and provide a more immersive training experience. Additionally, further research will aim to integrate AI-driven procedural learning to offer adaptive training pathways based on the individual needs of each user. Expanding the system to include more complex foundry operations, such as different casting techniques and advanced post-processing methods, will also be explored to offer a comprehensive training solution. Finally, increasing platform compatibility and reducing hardware requirements will make this VR foundry system more accessible to a broader audience, further elevating its impact on the future of metal casting education and training.

It is important to note that this paper does not include a formal user study or controlled experimental evaluation of training outcomes. Although preliminary feedback from a small group of users informed iterative design decisions, no quantitative or qualitative data were systematically collected or analyzed for this manuscript. Future work will involve a structured evaluation using pre/post assessments, observational data, and user interviews to investigate the system’s impact on learning retention, hazard recognition, and procedural accuracy. These studies will be crucial for validating the educational effectiveness of the VR training environment.