About Casting Hub Inc.
Built by Someone Who Has Actually Been on the Melt Deck
M. Saqib Qayyum, P.Eng Metallurgical Engineer | ISO 9001:2015 Lead Auditor | Lean Six Sigma Black Belt | MBA
There Are Consultants Who Have Read About Foundries. And Engineers Who Have Lived in Them.
I am the second kind.
I started my career at a central government metallurgical facility — not serving one foundry, but dozens.
Every week brought a different plant, a different alloy, a different failure mode. Gray iron one day, aluminum the next.
Sand casting in the morning, permanent mold in the afternoon.
That environment did something most careers never do: it forced me to develop real diagnostic instincts across the full spectrum
of metal casting, not just the narrow slice of one employer’s process.
That is where I learned to read a casting the way a doctor reads a patient. Not just what went wrong — but why, and what to
change before the next pour.
Fifteen years later, across ferrous and non-ferrous alloys — iron, steel, stainless, aluminum, copper — that instinct is still what I
bring to every engagement.
The Moment That Defined Casting Hub
When I joined a Canadian foundry, they were in serious trouble.
Their largest customer — one of Canada’s biggest pump design and supply companies — had placed a major order. The foundry was
losing money on every pour. Scrap rates were catastrophic. Six welders were working full-time just to salvage what came out of the
mold. The floor was bleeding cash and morale was gone.
I started from the beginning. Simulation-driven gating and risering redesign. Process discipline. Systematic defect analysis.
Back to the fundamentals that most shops skip when they’re under pressure.
The result: first-time 100% X-ray pass castings. Zero welding rework.
The foundry reached break-even in six months. It was profitable within a year.
That result didn’t come from a report. It came from standing on the floor, understanding the metal, and refusing to accept
“that’s just how it comes out” as an answer.
That is what Casting Hub delivers to every client.
Why I Started Casting Hub
I always wanted to work across many foundries, not just one. Early in my career, that government facility role gave me a taste of what it meant to solve problems at scale — walking into a plant, diagnosing the issue, fixing it, and moving to the next. I never lost that drive.
Casting Hub exists because small and mid-size foundries deserve access to the same level of metallurgical expertise, simulation capability, and quality systems discipline that large OEM suppliers take for granted. Most don’t have a full-time P.Eng on staff. Most don’t have someone who can run a casting simulation, redesign their gating system, and audit their ISO 9001 system in the same engagement.
Credentials & Qualifications
- P. Eng. – Professional Engineer, Licensed in Ontario
- ISO 9001:2015 Lead Auditor – Certified
- Lean Six Sigma Black Belt
- JHSC Certified – Joint Health & Safety Committe
- 15 years of hands-on foundry experience across ferrous and non-ferrous metalcasting.
Core Beliefs
- Data Over Guesswork: I replace ‘this is how we’ve always done it’ with simulation-validated, data-driven process design.
- Practicality Over Theory: Built for your operations — actionable, real-world solutions over academic ideas.
- Partnership Over Transaction: Your success defines ours — I work as an extension of your team, not a vendor.
- Continuous Improvement is Non-Negotiable: Progress isn’t a project; it’s a culture we help you build and sustain.
How I Work
Every engagement starts with listening — to your process data, your floor team, and your scrap reports. I combine simulation tools, ISO
discipline, and Lean Six Sigma methodology to build solutions that actually work in your environment, not just on paper.
I work remotely with foundries across Canada and the United States, and I bring the same precision to a virtual consultation that I
would bring standing beside your furnace.
If your castings are costing you more than they should, let’s talk.
Let’s build the future foundries
Book a free consultation to see how simulation and design optimization can cut project time, reduce scrap, and boost yield.
