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Blog post: 13/10/2025 3:34 pm

Author: Spark Team

VR SOP Training for Foundries & Metal Casting

Custom VR to control high-energy hazards and stabilise casting quality

Foundries blend molten metal, heavy handling and precise mould preparation. Errors in gating, pouring or shakeout quickly become scrap and safety incidents. Spark builds bespoke VR SOP training that replicates your furnaces, ladles, mould lines and quality gates—so crews rehearse hazardous and quality-critical tasks without exposure to heat or motion risks.

Foundry pain points we address

• High-energy hazards: tapping, ladle handling, spillage control and refractory checks.
• Mould & core quality: sand properties, venting, coating, bake cycles and assembly sequence.
• Pouring discipline: temperature windows, turbulence minimisation and gating balance.
• Defect prevention: shrinkage, misruns, gas porosity and inclusions.
• Post-cast steps: shakeout, riser removal, heat treat and dimensional inspection.

Our bespoke build pathway

1. SOP capture & hazard mapping: furnaces, melt chemistries, mould line controls and PPE.
2. Scenario design: tap-to-pour, mould assembly checks, temperature excursions and spill response.
3. AI avatar coaching: prompts for pre-pour checks, pour rate/angle and post-pour hold points.
4. Assessment & analytics: defect heatmaps, right-first-time, time-to-safe-state.
5. Integration: LMS links, multilingual content and role-specific modules (moulding, melt, QA).

Operational outcomes

• Fewer safety incidents and better control of molten-metal risks.
• Reduced scrap via consistent mould/core and pour discipline.
• Faster onboarding for seasonal and replacement labour.
• Audit-ready competence records for customer assurance.

Why Spark

Your training twin is built to your alloys, moulding process and quality standards—ensuring real-world transfer on the line.

Explore a bespoke foundry VR SOP trainer. Contact Spark.

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