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About the Role

The Casting Engineer is responsible for developing, optimizing, and supporting die casting manufacturing processes to ensure safe, efficient, and cost-effective production of high-quality cast components. This role works closely with design engineering, quality, maintenance, and production teams to drive continuous improvement, resolve manufacturing issues, and support new product launches.

Responsibilities

• Develop, implement, and optimize die casting processes to meet quality, productivity, and cost objectives.
• Support new product introduction (NPI) activities, including process development, trial runs, and production launch readiness.
• Collaborate with tooling suppliers and internal teams on die design, modifications, and maintenance strategies.
• Analyze casting defects such as porosity, blisters, soldering, flash, and shrinkage, and implement corrective actions.
• Establish and maintain process parameters and documentation.
• Conduct root cause analysis and lead problem-solving activities using tools such as 8D, Fishbone, 5 Why, and FMEA.
• Monitor and improve Overall Equipment Effectiveness (OEE), scrap rates, cycle times, and process capability.
• Support preventive and predictive maintenance programs for die casting equipment and tooling.
• Assist in evaluating and implementing automation solutions, robotics, and process monitoring technologies.
• Participate in capital equipment selection, installation, commissioning, and validation activities.
• Lead continuous improvement initiatives focused on safety, quality, delivery, and cost.
• Support environmental, health, and safety programs while ensuring compliance with company and regulatory requirements.
• Provide technical guidance and training to production personnel, technicians, and maintenance teams.

Requirements

• Bachelor's degree in Mechanical Engineering, Metallurgical Engineering, or related technical field.
• Minimum 2 years of experience in die casting manufacturing engineering.
• Experience with aluminum die casting processes.
• Strong understanding of die casting tooling, gating systems, venting, thermal management, and process optimization.
• Knowledge of casting defect analysis and metallurgical principles.
• Experience with statistical process control (SPC) and process capability analysis.
• Proficiency with CAD software (SolidWorks preferred).
• Strong problem-solving, analytical, and project management skills.
• Excellent communication and cross-functional collaboration abilities.
• Ability to work in a manufacturing environment with exposure to heat, noise, and industrial equipment.
• Ability to stand, walk, and move throughout the facility for extended periods.
• Ability to lift up to 25 pounds occasionally.
• Occasional travel to suppliers or customers as required.
• Must have the legal right to work in the US.
• Must be legally authorized to access export-controlled information and source code.

Skills

• Aluminum die casting processes
• Die casting tooling
• Gating systems
• Venting
• Thermal management
• Process optimization
• Casting defect analysis
• Metallurgical principles
• Statistical process control (SPC)
• Process capability analysis
• CAD software (SolidWorks preferred)
• Problem-solving
• Analytical skills
• Project management
• Communication
• Cross-functional collaboration
• Casting simulation software (MAGMASOFT, Flow-3D Cast, ProCAST, or equivalent)
• Lean Manufacturing
• Six Sigma
• Continuous improvement methodologies
• Robotics
• Automation
• Industry 4.0 technologies

Work Type

• Manufacturing environment

Experience Level

• Minimum 2 years of experience in die casting manufacturing engineering
• 5+ years of die casting engineering experience in an aerospace manufacturing environment

Education Level

• Bachelor's degree in Mechanical Engineering, Metallurgical Engineering, or related technical field.