Casting Process Engineer – Development Program

General Motors; Bedford (IN); On-site; USD 65,000 - 90,000; Full time

Job summary

General Motors in Bedford, Indiana, is seeking a Casting Process Engineer for a two-year development program. The role provides four rotations across three manufacturing sites, accelerating technical growth and knowledge of GM casting operations, with placement into a full-time assignment at the home location after completion.

You will collaborate with cross-functional teams—Quality, Launch, Tooling, Melting and Metallurgy—and develop processes, tooling, and controls while gaining hands-on

Qualifications

• Pursuing/belong to a Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Material Science, Industrial Engineering, Engineering Technology, or Metallurgy.
• Must be graduating between May 2025 and December 2026.
• Able to work full-time, 40 hours per week and overtime when required.
• Must be willing to work in a plant environment.

Responsibilities

• Work individually on specific programs yet collaboratively with the Process Engineering Team, Launch Team, Quality, Design, Tooling, Melting and Metallurgy, Product Engineering, and other support groups.
• Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering procedures
• Support testing and installations of equipment, tooling and technologies both on and off site
• Lead, support and present the analysis of casting defects
• Assist in process, tooling and equipment testing, troubleshooting and implementations
• Develop process documentation, Process flow diagrams, Control plans, PFMEA, standard work documents, and related technical documents as necessary for a program launch
• Analyze first-time quality data and optimize processes using DOE, DFSS green belt, and related statistical tools
• Manage Process Controls plans, QS-Stat and Flexnet software, and quality systems
• Perform both non-destructive and destructive testing procedures for casting investigation and analysis (CMM, leak testing, x ray, CT, thermal, lab specimen prep, chemistry, density, mechanical, etc.)
• On site work, working on shop floor, hands on equipment, understanding of casting shop activity.

Skills

Full-time availability

Education

Bachelor's or Master's degree in Engineering/Metallurgy

Job description

The Role

The Casting/Manufacturing Engineering team’s Casting Process Engineer role is a two-year casting development program.

Job Description

The Casting/Manufacturing Engineering team’s Casting Process Engineer role is a two-year casting development program. The Process Engineer position is a direct-hire role aligned to a designated home location within our casting manufacturing organization. As part of the onboarding and development strategy for this role, the successful candidate will participate in a structured two-year rotational experience consisting of four assignments across three manufacturing sites. The rotational assignments are intended to accelerate technical development, expand enterprise casting knowledge, and deepen understanding of GM manufacturing systems and operations. Following completion of the rotational experience, the employee will be placed in a full-time assignment at their original home location.

Potential assignments may include:

• Quality Engineering
• Project Launch Execution Support
• Production Process Engineering Support – Casting processes
• Production Process Engineering Support – Machining Processes
• Tooling Design
• Melting/Metallurgy lab

The Team

The Process Engineering Team excels in the development, testing, implementation and execution of new casting programs, platforms, and technology. This group is unique in that by working with and across multiple levels of the GM technical groups, vendors and suppliers, the complex problems of casting projects are developed into controlled manufacturing processes.

The specific purpose of this position is to perform casting manufacturing projects by following a systematic engineering process of evaluation, development, validations, technology transfer leading into and supporting the production launch and processing. Specifically, the individual would be responsible and directly involved in the development of manufacturing processes, equipment, tooling and alternatives, sequences, operations, utilizations to produce castings.

What You'll Do

• Ability to work individually on specific programs yet collaboratively with the Process Engineering Team, Launch Team, Quality, Design, Tooling, Melting and Metallurgy, Product Engineering, and other support groups
• Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering procedures
• Support testing and installations of equipment, tooling and technologies both on and off site
• Lead, support and present the analysis of casting defects
• Assist in process, tooling and equipment testing, troubleshooting and implementations
• Develop process documentation, Process flow diagrams, Control plans, PFMEA, standard work documents, and related technical documents as necessary for a program launch
• Analyze first-time quality data and optimize processes using DOE, DFSS green belt, and related statistical tools
• Manage Process Controls plans, QS-Stat and Flexnet software, and quality systems
• Perform both non-destructive and destructive testing procedures for casting investigation and analysis (CMM, leak testing, x ray, CT, thermal, lab specimen prep, chemistry, density, mechanical, etc.)
• On site work, working on shop floor, hands on equipment, understanding of casting shop activity.

Your Skills & Abilities (Required Qualifications)

• Pursuit of a Bachelor’s or Master's degree in Manufacturing Engineering, Mechanical Engineering, Material Science, Industrial Engineering, Engineering Technology, or Metallurgy
• Must be graduating between May 2025 and December 2026
• Able to work full-time, 40 hours per week and overtime when required
• Must be willing to work in a plant environment

What Will Give You a Competitive Edge (Preferred Qualifications)

• Experience in a plant environment or similar
• Training in foundry processes
• Training in process engineering procedures and disciplines
• Basic knowledge of Magma, Flow 3D, simulation software
• Basic knowledge of NX, Catia or any 3D design software
• Degree courses with a metal casting focus

Relocation and Immigration

GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc.).

This role is categorized as onsite. This means the successful candidate is expected to report to Bedford, Defiance, or Saginaw Foundry on a full-time basis.

This job may be eligible for relocation benefits.

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