The 2025 Cast in Steel Competition is in full swing, and Midwest Metal Products is thrilled to be partnering with Virginia Tech’s College of Material Science and Engineering to bring history to life. This year’s challenge? Crafting a model of George Washington’s iconic sword.
As a leader in metal manufacturing, we were honored to play a crucial role in this prestigious competition. Virginia Tech’s team, the Iron Maidens, had a great start but needed expert support in key areas. That’s where we came in.
Our Role in the Project
- Computer Modeling & Simulation: We provided the Virginia Tech team with a CAD model of the sword, which they could use to run solidification simulation trials on to determine the best approach to making a sound casting
- Casting Guidance: With our extensive experience in metallurgy and casting, we provided expert insights to enhance the design for manufacturing.
- Material Supply: We supplied the necessary materials to ensure the project’s success.
- Blanchard Grinding: Using our Blanchard grinder, we were able to quickly remove material to make the sword blanks the desired thickness and straightness.
This isn’t our first time working alongside Virginia Tech. Back in 2020, we collaborated with their team for the Cast in Steel competition when they crafted a Bowie Knife that won the prize for “Best Performance.” We’re thrilled to build on our past success and push the boundaries of what’s possible together.
Meet the Iron Maidens’ Team
The Virginia Tech team is made up of dedicated and talented individuals who poured their hearts into this project:
- Alan Driusctiz – Faculty Advisor
- Ashley Lacy
- Mitchell McClure
- Bethany Gansemer
- Ashton O’Rourke
- Nikki Powell
A Student’s Perspective: Ashley’s Experience
For Ashley Lacy, one of the students on the project, the most rewarding part was seeing the sword come together at the last moment:
“We created many individual components separately, and since most of the work came together at the last minute, seeing everything finally take shape was incredible. It was a beautiful moment to see that our hard work had paid off in the end.”
Ashley also highlighted the crucial role Midwest Metal Products played in their success:
“Midwest Metal Products was an invaluable partner in this project! As Materials Science and Engineering majors at VT, we aren’t formally trained in CAD, but we needed CAD files for the simulation software we used (MAGMA, which simulates metal flow in casting). David (Michalski, MMP Foundry Engineer) was incredibly generous in producing three different CAD models for us—one with a channel, one without, and one with a tapered design. Having those files allowed me to develop different gating systems in MAGMA using various patterns.”
“Throughout the project, Jeanne (Wagner, MMP Technical Director) consistently checked in, offering assistance and meeting with us multiple times to discuss the next steps. They also provided charge materials for our H13 steel and helped with Blanchard grinding three different swords. Midwest Metal Products’ support was crucial to our success. We truly couldn’t have completed this project without them.”
“This project was an incredible opportunity, and we were so fortunate to have such a supportive industry partner. I’ll be graduating in May, but I hope future VT teams have the chance to collaborate again!”
Competition Details
The competition will culminate in a series of rigorous tests from April 9-11, with the awards ceremony set for April 12 in Atlanta, Georgia. Teams from across the nation will showcase their craftsmanship, precision, and engineering expertise as they compete to create the best steel recreation of George Washington’s sword.
We’re honored to be part of this exciting journey and couldn’t be prouder of the Iron Maidens. We wish them the best of luck in the competition and can’t wait to see the final product in action! Stay tuned for updates!
For more information about the event including past steel creations and winners, visit: SFSA Cast in Steel Competition.
