Process Engineer

CastAlum; Welshpool; On-site; GBP 40,000 - 55,000; Full time

Job summary

A leading aluminium manufacturing company in Welshpool is seeking a Process Engineer to lead technical decision-making in the high-pressure die casting department. You will ensure optimal casting processes to meet quality and productivity targets, working closely with various departments. The ideal candidate will have a strong background in HPDC, problem-solving abilities, and a relevant engineering degree. Join a well-established firm that values innovation and efficiency in manufacturing.

Qualifications

• Strong background in high-pressure die casting, ideally in automotive-grade environments.
• Proven experience analysing shot profiles and casting defects.
• Competent with process documentation and data-driven decision making.

Responsibilities

• Act as the on-shift technical decision maker for all HPDC processes.
• Provide direction to Process Technicians on process adjustments.
• Ensure all process changes are controlled and logged.

Skills

High-pressure die casting experience

Technical decision-making

Problem-solving ability

Knowledge of hydraulic systems

Education

Degree or HNC/HND in Mechanical, Manufacturing, Metallurgy or related field

Tools

Shot monitoring software

SPC analysis tools

Job description

CastAlum is an internationally acclaimed aluminium die casting and machining centre located in Welshpool, UK. The site was a Greenfield development in the winter of 2000-2001, serving one customer only.

20 years on, the company supplies parts to the UK, Europe, Canada, and Mexico. We have grown from die casting aluminium parts only to supplying a range of products (using high pressure die casting, squeeze die casting, and machining). We can supply aluminium components as cast, cast & machined, or assembled & tested according to the needs of our customers.

Job Description

The Process Engineer is the on-shift technical authority responsible for leading all process-related decision making across the high-pressure die casting (HPDC) department. The role ensures casting processes are stable, capable, and optimised to deliver quality, safety, and productivity targets. Working closely with Process Technicians & the Production, Maintenance, Toolroom and Quality departments. The Process Engineer provides advanced technical support, root cause analysis, and methodical process optimisation using recognised die casting methodologies.

Key Responsibilities

Leadership & Decision Making

• Act as the highest level of on-shift technical decision maker for all HPDC processes.
• Provide direction to Process Technicians on process adjustments, die changes, and fault diagnosis.
• Lead start-ups, restarts, die trials, parameter validation, and approval of first-off samples.
• Set up and be involved in all automation processes for Die cast Cells. (6 axis robots, Conveyor systems)
• Ensure that all process changes are controlled, logged, and aligned with engineering standards.
• Make safe, effective decisions under time pressure to maintain production and minimise downtime.

Work closely with the Process Supervisor and Manager on company objectives.

Qualifications

Skills, Experience & Qualifications

• Strong background in high-pressure die casting (HPDC), ideally in automotive-grade environments.
• Proven experience analysing shot profiles, thermal behaviour, and casting defects.
• Ability to lead technical decision-making and guide teams under pressure.
• Strong understanding of gating, venting, vacuum systems, die cooling, and metal flow dynamics.
• Proven problem-solving ability using structured methods and data-driven decision making.
• Competent with shot monitoring software, SPC analysis, and process documentation.
• Degree or HNC/HND in Mechanical, Manufacturing, Metallurgy, or related engineering field.
• Experience with aluminium alloys.
• Familiarity with DOE methods, Six Sigma, and statistical tools.
• Strong understanding of hydraulic systems, accumulators, and servo-controlled shot systems.
• Experience in continuous improvement programs (Kaizen, Lean).
• KUKA and ABB 6 axis robot knowledge / experience.