Skuld LLC

Navigating Heat Treaters’ Most Defining Moments

We like to celebrate the wins for good reason: they inspire us when times get tough. Regardless of where you find yourself in the North American heat treat community, you will face challenges that may redirect your life and prompt you to question your goals or values. Given this universal experience, we asked respected individuals from across the industry to share the hardest decisions of their professional lives. Just as successes inspire resilience, these challenges offer lessons in navigating the toughest moments of your career.

This inspiring piece was first released in Heat Treat Today’s September 2025 Annual People of Heat Treat print edition.


“No Jerks” Rule, with Sarah Jordan

Sarah Jordan
Founder & CEO
Skuld, LLC

For Sarah Jordan, president and CEO of the cutting-edge casting startup Skuld LLC, hard decisions have paved the path of her career. An earnest visionary — and as down-to-earth as they come — Sarah has made a habit of launching startups for the metal processing industry. Today, she leads a team that has developed a toolless, net-shape casting process and the equipment to perform it, advancing the way parts are formed while minimizing post-processing needs.

It comes to no surprise that her hardest decision came while forging this path. In 2009, Sarah’s first startup, Aesir Metals, faced fall-out from the 2008 economic recession. The impact was most acute when their largest customer informed them that they were unable to pay.

Faced with this reality, Sarah had to make the painful choice to close the company. Just after Christmas that year, every employee was let go. “And that’s awful when everybody’s…you know, they’re counting on you, their families are counting on you.” It was her first time navigating such a challenge, and while it was difficult, it became a formative experience.

Leading her current company, Sarah operates with a “‘no jerks’ rule.” She says culture and people are critical, and the postmortem of Aesir Metals revealed other opportunities for improvement. While mistakes are inevitable — learning requires that — she moves forward, determined not to repeat the same ones.

Upgrade Your Skillset, with Kevin Walters

Kevin Walters
Research & Development Manager
OMG Inc.

Kevin Walters‘s official title is R&D manager at OMG Inc. out in Massachusetts — however, his nickname “Father of Interns” is extremely fitting. With decades of engineering experience, Kevin has dedicated 25 of them (and counting) to mentoring interns, first at Spalding Sports Worldwide and now at OMG. Using his own career for reference, he tells them this story.

Approaching his forties with four boys near or in their teenage years, Kevin began thinking seriously about his career trajectory. He knew that to stay relevant in engineering, he needed to expand his skillset. In this field, the rule is simple: upgrade your abilities or risk becoming obsolete. The question was how.

“I’m a guy who likes to fix stuff — work with my hands,” Kevin told me. The typical career-advancement routes didn’t seem like the right fit: waiting for an opportunity to open up in the company could take too long, a doctorate might pigeonhole him into academia, and an MBA didn’t align with his engineering focus. It took five years of consideration, conversation, and research to find the right path.

That opportunity appeared when he learned about a management degree specifically tailored for engineers. With Spalding’s full “blessing” and tuition reimbursement program, Kevin enrolled at Western New England University, taking two courses per year while balancing his job and his sons’ baseball games. In five years, he had earned his Master’s of Science in Engineering Management.

These kinds of programs have become more widely available, and Kevin encourages his interns to pursue them. “Engineers, if they don’t upgrade their skillset, become obsolete,” he says. “I see too many engineers who graduated with their four-year degree — did great things at the beginning of their career — but because technology is advancing and they’re not learning with it, they are not as useful as they used to be.”

Each summer, Kevin continues mentoring one or two interns, urging them to think strategically about building their résumés and preparing for an industry that never stops moving.

It’s the People, with Dan Bender

Dan Bender
Director of Sales
Control Concepts

As Dan Bender reflects on his 47 years in industry, many as director of sales at Control Concepts, one priority has guided him: bring in business so the people in manufacturing have a job, can feed their families, and keep a roof over their heads.

In the late ’80s and early ’90s, there were a lot of mergers and acquisitions of companies by holding firms. A general attitude that “work is work” within industry started to emerge. He observed that people were being treated as just another factor of direct manufacturing costs.

This inhumane approach was augmented by a larger lack of pride in the business by the leadership. He also perceived that businesses were treated as financial investments; leadership seemed to be just concerned with flipping the company for a profit. Eventually, these factors reached Dan’s workplace.

Desiring more from his employer and wanting to be useful and productive in a place where people mattered, he parted ways. He reflects, “I left a pretty good job and went out to try some other things, realizing I still had a family to support.”

Over the next few years, he explored different roles, leaning on the counsel of friends and mentors from outside the heat treat industry, many of them from his church. Then, in 2008, the recession hit. Dan was working for a European company when it eliminated nearly all North American positions, and for the first time in his career, he was out of a job.

“That was tough,” he commented. “That was a hard, a hard thing…I did some interviews, I had some possibilities, I had some decent things, but I wanted to find somewhere where…people are important.”

His faith was central to that search, and in time, he found the right fit at Control Concepts. While it was not the best offer at the time, it was “what made me feel good, and it [did turn] out to be very financially rewarding for me.”

Choosing to stick with his principles also meant staying in an industry where he had built decades-long relationships. Dan says he looks forward to seeing those connections at tradeshows like Heat Treat 2025 this fall and Furnaces North America next year. “It’s to me, you know…that’s a blessing that I can have conversations with those people and feel a real sense of knowing they are very interested in what you’re doing as well as you being interested in what they’re doing at this stage in their career and your life.” Serving the heat treat industry, and the people in it, is why Dan has no plans to retire anytime soon.

Never Stand Still, with Bill Stuehr

William (Bill) Stuehr
President & CEO
Induction Tooling Inc.

What do you do when an unforeseen market collapse changes the fabric of your business? William (Bill) Stuehr, engineer, founder, and CEO of Induction Tooling Inc., has a clear answer: make a plan and move forward. “I’m a pragmatist,” he says. “I look at things the way they are, then I make decisions and proceed with what has to be done. That’s all.”

In 2005, Bill built a brand-new facility to expand his operations from 14,000 to 30,000 square feet. Business had been picking up for induction heating since the 1980s and ’90s, and manufacturers of driveline components were interested in induction. Induction was becoming more accepted on two fronts: first, as a green energy source; second, as an integrated manufacturing step in cell production, allowing automotive components such as wheel bearings and axle shafts to come out finished at the end of the line. With the expectation to expand to 50 employees by 2015, the city even granted Induction Tooling a tax abatement to encourage expansion and boost the local economy.

The critical moment happened in 2009, beginning on the heels of the 2008 financial crisis. With the housing collapse, people stopped purchasing automobiles, and the automotive industry went reeling. In April and June, General Motors and Chrysler appeared before U.S. Congress after filing for bankruptcy. Bill’s tier 1 automotive manufacturing customers began shutting down operations. “I had never seen it in my career, ever.”

Work was running out. Bill made the hardest decision of his career: “I had to lay off half of my workforce. I went from 28 people to 14 in less than a year.” Some of them had been with him since he started in the late 1970s. “It was out of my control. I tried to keep them on as long as possible without suffering the financial hardship of my own.” Even in hard times, the company covered all employee medical insurance, a practice Bill maintains to this day.

By 2012, the market showed signs of recovery. Bill pivoted the business to focus almost exclusively on CNC automation for rebuilding tooling — a move that met the needs of their tier 1 customers with high production rates and sidestepped the challenges of rehiring or retraining a large workforce.

Commenting on today’s market, Bill revealed it had never truly recovered. “The buyers of the automotive companies had the time to seek outsourcing worldwide.” He continued, explaining that over the course of the four years that followed the crash, there was enough offshoring of driveline components to an enthusiastic, energetic workforce with new facilities and abilities. Reshoring to the U.S. has not gained back the momentum that it had, though perhaps that will change with the priorities of the current U.S. administration.

From those years came a few lasting lessons. First, embrace automation to keep the business profitable, especially when attracting young talent is a struggle. Second, when hard times come, make a plan and commit — but remember that you can’t control time, the weather, or other people. Bill sums it up with gritty simplicity: “You never stand still; you just keep going. ‘What do I have to do and how can I get it done?’ That’s it.”


Bethany Leone
Managing Editor
Heat Treat Today
Contact: Bethany Leone at bethany@heattreattoday.com

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10 News Chatter to Keep You Current

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry. Enjoy these 10 news items, featuring Plibrico Company’s new CEO, Pratt and Whitney‘s 100 years in aerospace, Stack Metallurgical Group‘s new cryotherm technology, and more!


Equipment

1. SMS Group and Jiangsu Pacific Precision Forging commissioned a 31.5-MN closed-die forging press for large-scale production of aluminum suspension components.

2. Stack Metallurgical Group in Portland has commissioned a new TRU-CRYOTHERM made by McLaughlin Furnace Group. The addition has a 4000 pound capacity.

3. Mercer Technologies Inc has shipped a MerVac RVF-242436 vacuum furnace. The furnace has a completely remanufactured vessel, with a rebuilt pumping system, hot zone, heating element power supply, and water circulation system.

Company & Personnel

4. Rodney Strasser has joined Ipsen USA as the regional service manager for the Southeast Region. Operating out of Atlanta, Georgia, Strasser will be responsible for coordinating and leading a team of Ipsen service technicians that serve Ipsen clients in Delaware, Maryland, Virginia, North Carolina, South Carolina, Georgia, Tennessee, Alabama, and Florida.

5. Plibrico Company has announced the appointment of John Paul Surdo as president and CEO following the retirement of the longtime president and CEO, Brad Taylor.

6. Delamin Nitriding Salts (DNS), a subsidiary of Parker Netsushori Kogyo of Japan, announced the acquisition of Avion Manufacturing, a leading producer of high-quality stop-off paints, headquartered in Medina, Ohio. This acquisition enhances DNS’s capabilities in providing high quality surface treatment solutions in the heat treatment industry.

Kudos

7. Skuld, LLC celebrated ten years as a company. Their team spent time to celebrate and reminisce as well as to look to the company’s future.

8. Bob Hill, president of Solar Atmospheres, received the MTI Heritage Award. The MTI Heritage Award recognizes an individual’s lifetime commitment and significant contributions to advancing the commercial heat treating industry.

9. Pratt and Whitney celebrated 100 years in the aerospace industry. With over 90,000 engines in service around the globe, they have pushed the boundaries of aviation and human flight.

10. Alleima has met its sustainability targets, which were validated by the Science Based Targets initiative (SBTi), and are now aligned with the latest climate research. These targets mean that Alleima is reducing its Scope 1 and 2 CO2 emissions by more than 54% and Scope 3 emissions by 28% by 2030, using 2019 as the base year.



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Flagship Casting Machine Shipped for Next-Gen Manufacturers

A company in advanced metal casting technologies has shipped its first commercial additive manufacturing evaporative casting (AMEC) machine to the University of Tennessee, Knoxville (UTK). The system will be installed at UTK’s manufacturing research facility, where it will support continuing education, casting research, and workforce development in next-generation manufacturing.

Lightning Metal LM-16 is Skuld LLC‘s flagship machine for additive manufacturing evaporative casting (AMEC). The machine is a tool-less, net-shape casting process capable of producing aerospace grade aluminum and other high-performance alloys with minimal post-processing. The system enables rapid prototyping, reduced lead times, and flexible alloy compatibility, making it ideal for both industrial and academic environments.

The Lightning Metal LM-16 AMEC machine by Skuld
Source: Skuld LLC
Sarah Jordan
Founder & CEO
Skuld, LLC
Source: Author

“This milestone represents…a signal that advanced casting is entering a new era,” said Sarah Jordan, co-founder and chief executive officer at Skuld. “The University of Tennessee is a national leader in manufacturing innovation, and we’re proud to support their mission with a system that bridges research and real-world application.”

Adam Penna
Director, Sales and Marketing
Skuld
Source: Linkedin

UTK will use Lightning Metal LM-16 platform to expand its materials science curriculum, conduct applied research in casting and alloy development, and provide hands-on training for students and professionals entering the manufacturing workforce.

“This is exactly the kind of partnership we envisioned when we launched the Lightning Metal platform,” said Adam J. Penna, director of sales and marketing at Skuld. “It’s a platform that empowers innovation in evaporative casting utilizing 3D printing for improved features like edges and surfaces while also reducing the need for tooling cost…whether you’re solving supply chain challenges or training the next generation of engineers.”

The Technology

Skuld’s AMEC technology merges lost foam with polymer 3D-printing. Heating up to around 2000°F, the machine operates as an automated micro-foundry. The Lightning Metal LM-16 removes the safety issues of handling molten metal and is perfect for small, custom, one-off aluminum parts fasteners. It makes products in a 7″ cube, melting approximately 16lbs of aluminum, and can also process brass or bronze.

The machine is sized to be able to move through standard doorways and utilizes single-phase power, like a dryer plug.

The casting works by utilizing a hollow polymer shape in place of lost foam, where the molten metal vaporizes the polymer. This is a subset of the casting field called lost foam, which is a variation on lost wax investment casting, and eliminates around 90% of process steps, making for fewer costs and a faster process. The mold is insulated with a thin ceramic shell, ceramic beads, a metal container called a flask, and unbonded beads.

Heat Treat Today asked what difficulties Skuld faced in developing this technology. The development process faced several unique hurdles, such as heat retention due its small size (compared with a large furnace), as well as crafting the machine’s automation while not allowing it to be hackable.

Applications

SBIR awarded to Skuld LLC
Source: Skuld LLC

The Lightning Metal LM-16 is for those without an in-house foundry. It works well for replacement parts for in-house heat treatment, for example: hooks, baskets, or rollers. The machine can also produce spare parts or be utilized for prototyping pieces that can be used by higher volume machines. The Lightning Metal LM-16 operates well at around one hundred pieces per year.

The AMEC technology eliminates machining (which reducing costs for clean machining), and drives down the cost substantially associated with cooling for lost foam. The process also avoids HIPing, reducing the need for powder bed fusion parts.

The system enables reverse-engineering for discontinued items, and could be particularly applicable for heavy equipment, agriculture, compressors, and railroads.

The Lightning Metal LM-16 deployment marks a major step in Skuld’s commercialization strategy, following over $9 million in Department of Defense contracts and successful pilot programs with the U.S. Air Force and Defense Logistics Agency. The company was recently awarded an SBIR for additive manufacturing.

For more information on this technological innovation, please contact Adam Penna at apenna@skuldllc.com.



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Stainless Corrosion


I’m starting to see Cybertrucks out in the wild more, so I decided to talk about stainless corrosion for #MetallurgyMonday. (If you don’t know what #MetallurgyMonday is, it is a weekly educational post on metallurgy topics that I’ve been writing on LinkedIn for the past two years.)

First a little up front. I’m not a fan of the aesthetics of the Tesla Cybertruck. Plus, we need about twice the load capacity for our work purposes since Skuld actually uses our truck as a truck.

More to the point, stainless steel is not rust proof. It is corrosion resistant and will rust in a lot of circumstances. 

To understand why, we need to understand what prevents corrosion in the first place. The key elements are chromium and nickel. Chromium reacts with oxygen to create a thin layer of chromium oxide. This is on the surface and blocks further oxidizing of the underlying layers. Meanwhile, the nickel enhances the corrosion resistance. It also makes the material more formable and weldable.

The short story is that if the chromium oxide layer gets compromised, stainless steel will corrode.

Improper heat treating can also contribute to stress corrosion cracking.

Sarah Jordan
  1. Pitting corrosion: If you have a scratch or a pit, this can damage the protective film, and then corrosion begins. It’s worse in environments with chloride ions, such as seawater or pool water. Chlorides break down the passive layer, leading to rapid and severe corrosion in small areas.
  2. Crevice corrosion: This occurs when two objects come together, especially things like fasteners or where there is a gasket. Inside the crevice you will have a lack of oxygen. The lack of oxygen prevents the reformation of the protective chromium oxide layer. Once corrosion gets started, it can get very severe by propagating in the crevice.
  3. Stress corrosion cracking (SCC): Corrosion is made worse where there is a combined effect of tensile stress and a corrosive environment. It typically affects stainless steel used in structural applications that are exposed to chloride or sulfides. SCC can cause sudden and catastrophic failure of the metal structure.
  4. Galvanic corrosion: Galvanic corrosion happens when two metals are put together. One of them almost always wants to preferentially corrode. The one that corrodes is the one that is higher on the galvanic series. 
  5. Intergranular corrosion (IGC): Sometimes this is called intergranular attack (IGA). In this case, corrosion occurs preferentially at grain boundaries. This can occur in stainless if the grain boundaries get depleted of chromium because a minimum amount is needed to ensure the passive film can form to protect the metal. When this occurs, there can also be localized galvanic corrosion.
  6. Composition variation: If the composition has segregation, then there are some areas that have less of the corrosion-helping elements. And on top of that, galvanic corrosion can start happening within the material.

What does all of this have to do with heat treating? Improper heat treating can contribute to corrosion.

For instance, intergranular corrosion can be caused if the material is exposed to 842–1562°F (450–850°C) for too long as this will cause chromium carbide to form at the grain boundaries and deplete the chromium. This process is called “sensitization.” It is avoided by making sure quench rates are fast enough through the risky temperature range.

A somewhat similar situation can occur during heat treating if sigma phase forms in super duplex stainless steel. Sigma phase is an iron chromium phase which can also deplete the chromium.

Improper heat treating can also contribute to stress corrosion cracking. When material is quenched, it can cause residual stresses that, if not relieved, can become an issue.

Corrosion in stainless steel can often be traced to improper heat treatment. When stainless steel is heated between 842–1562°F (450–850°C), chromium carbides can form at the grain boundaries, depleting the surrounding areas of chromium and making them susceptible to corrosion.

All of this to say, things like the Cybertruck (or for that matter stainless fridges and appliances) can be prone to corrosion since they are exposed to a lot of abuse and aggressive environments. It is critical to ensure they are properly manufactured, including good heat treating practices. It is also critical to provide them with proper maintenance to keep the corrosion resistance and appearance lasting as long as possible.

About the Author:

Sarah Jordan
Founder & CEO
Skuld, LLC
Source: Author

Sarah Jordan is an accomplished metallurgical engineer and entrepreneur. She received a bachelor’s of science and master’s of science in this discipline from The Ohio State University and has been pursuing a PhD in Metallurgical Engineering from WPI. Skuld is a certified WOSB and EDWOSB startup focused on 3D printing, advanced manufacturing, and advanced materials.


For more information, contact Sarah at her LinkedIn profile: Sarah Jordan | LinkedIn.


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Skuld Expanding by Opening New Foundry & Manufacturing Facility

HTD Size-PR Logo

Skuld LLC announced that they had purchased the site belonging to the former Champion Foundry in Piqua, Ohio, a gray and iron foundry that had closed in March 2017. The company will continue to be focused on innovation in the metals industry, serving their clients through a number of innovations related to novel materials and manufacturing technologies.

The four buildings with nearly 32,000 square feet of space are being refurbished to be capable of casting a wide range of ferrous metals (gray, ductile iron, steels) and nonferrous metals (aluminum, brass, bronze, copper, nickel alloys). The plant will initially have 3,000 tons of capacity but plans are in place to expand to ten times that capacity in the next few years.

Skuld will be installing machining, foam blowing, a printer farm, and heat treating, adding to their current 5 small heat treat furnaces and adding to their operations, which primarily consist of lost foam casting. The new installations will aid the company as they serve the defense, tooling, and heavy equipment industries. They are also beginning to target production of heat treat fixtures and baskets.

Sarah Jordan, CEO, Skuld LLC

Production at the new site is scheduled to begin in April 2024. Sarah Jordan, CEO of Skuld LLC, commented, "Skuld is looking forward to getting our induction melting furnaces installed so that we can produce higher temperature iron, steel, and nickel alloy castings." She continued, "many [heat treaters] have custom furnace components and fixtures that require high temperature metals. These parts can have extremely long lead times, sometimes over a year, which is a problem if they are stocked out." By using their new tooling free processes, Jordan says that they can help clients drive lead times down to less than a month, if not a day for emergency spares.

Skuld is a company founded by two metallurgical engineers, Mark DeBruin and Sarah Jordan, with ties to the heat treat industry. DeBruin is the former CTO of Thermal Process Holdings. Jordan formerly worked in heat treating at Timken and Commercial Metals and was a staff engineer for Nadcap heat treat.

The full press release from Skuld LLC is available upon request.


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Heat Treating AM Parts — Need To Know Difficulties and Solutions for Engineers

op-ed

Metal 3D additive manufacturing has grown dramatically in the last five years. Nearly every metal printed part needs to be heat treated, but this presents some challenges. This article will address some of the challenges that a heat treater faces when working with these parts.

This Technical Tuesday article, written by Mark DeBruin, metallurgical engineer and CTO of Skuld LLC, was originally published in December 2023’s Medical and Energy magazine.


Mark DeBruin Metallurgical Engineer and CTO Skuld LLC

In my experience, on average, about 10% of all 3D metal printed parts break during heat treatment; this number varies depending on the printer and the unique facility. While materials can be printed with wire or even metal foils, I’m going to mainly focus on the approximately 85% of all metal 3D printed parts that are made from metal powder and either welded or sintered together.

Most metal printed parts normally have heat added to them after printing. In addition to the heat of the printing process and wire electrical discharge machining (EDM) process to separate the part from the build plate, heat may be added up to five times. These steps are:

  1. Burnout and sintering (for some processes such as binder jet and bound powder extrusion)
  2. Stress relieving
  3. Hot isostatic pressing (HIP)
  4. Austenitizing (and quenching)
  5. Tempering

3D printing can create a non-uniform microstructure, but it will also give properties the client does not normally desire.
Heat treating makes the microstructure more uniform and can improve the properties. Please note that heat treating 3D printed parts will never cause the microstructure to match a heat treated wrought or cast microstructure. The microstructure after heat treating depends on the starting point, which is fundamentally different.

If the part is not properly sintered, there is a high chance it will break during heat treatment. It may also exhaust gases, which can damage the heat treat furnace. The off gases will recondense on the furnace walls causing the furnace to malfunction and to need repair. This can potentially cost hundreds of thousands of dollars.

During powder 3D printing, there is a wide variety of defects that can occur. These include oxide inclusions, voids, unbonded powder, or even cracks that occur due to the high stresses during printing. Even if there are not actual defects, the printing process tends to leave a highly stressed structure. All of these factors contribute to causing a print to break as the inconsistent material may have erratic properties.

In a vacuum furnace, voids can be internal and have entrapped gas. Under a vacuum, these can break. Even if something was HIP processed, the pores can open up and break. Even if they do not break and heat is applied, the metal will heat at different rates due to the entrapped gas.

Figure 1. Macroscopic view of a 3D printed surface (left) compared to machined surface (right) (Source: Skuld LLC)

There are also issues during quenching due to the differences in the surface finish. In machining, the surface is removed so there are not stress concentrators. In 3D printing, there are sharp, internal crevices that can be inherent to the process that act as natural stress risers (see Figure 1). These can also cause cracking.

When 3D printed parts break, they may just crack. This can result in oil leaking into the parts, leading to problems in subsequent steps.

Figure 2. Example wire mesh basket (Source: Skuld LLC)

However, some parts will violently shatter. This can happen when pulling a vacuum, during ramping, or during quenching. This can also cause massive damage to the furnace or heating elements. It can potentially also injure heat treat operators.

A lot of heat treaters protect their equipment by putting the parts into a wire mesh backet (Figure 2). This protects the equipment if a piece breaks apart in the furnace, and if a piece breaks in the oil, it can be found.

Print defects in metal 3D printed parts can be a challenge to a heat treater. Clients often place blame on the heat treater when parts are damaged, even though cracking or shattering is due to problems already present in the materials as they had arrived at the heat treater. As a final piece of advice, heat treaters should use contract terms that limit their risks in these situations as well as to proactively protect their equipment and personnel.

About The Author

Mark DeBruin is a metallurgical engineer currently working as the chief technical officer at Skuld LLC. Mark has started five foundries and has worked at numerous heat treat locations in multiple countries, including being the prior CTO of Thermal Process Holdings, plant manager at Delta H
Technologies,
and general manager at SST Foundry Vietnam.

For more information:
Contact Mark at mdebruin@skuldllc.com


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