Casting Process Engineer – Development Program

General Motors; Tennessee; On-site; USD 85,000 - 110,000; Full time

Job summary

General Motors is seeking a Process Engineer for a two-year casting development program. The role features four assignments across three manufacturing sites, designed to accelerate technical growth and deepen casting knowledge.

After rotations, you’ll transition to a full-time role at your home location. The program emphasizes hands-on work in casting processes, quality improvement, and collaboration across multiple GM technical groups.

Qualifications

• Pursuing a Bachelor's or Master's degree in a technical field relevant to casting and manufacturing.
• Graduating between May 2025 and December 2026.
• Willingness to work full-time (40 hours/week) and overtime as required.
• Willingness to work in a plant environment.

Responsibilities

• Collaborate with Process Engineering, Launch, Quality, Design, Tooling, and Metallurgy teams to execute casting programs.
• Support Manufacturing Validations, Build Plans, PPAP, and related engineering procedures for launches.
• Assist in testing and installation of equipment, tooling, and technologies on- and off-site.
• Lead and present analysis of casting defects and reduction efforts.
• Develop process documentation and quality systems for program launches.

Education

Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Material Science, Industrial Engineering, Engineering Technology, or Metallurgy

Tools

Magma

Flow 3D

NX

Catia

Job description

Job Description

The Role:

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 weekand 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

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.

About GM

Our vision is a world with Zero Crashes, Zero Emissions and Zero Congestion and we embrace the responsibility to lead the change that will make our world better, safer and more equitable for all.

Why Join Us

We believe we all must make a choice every day – individually and collectively – to drive meaningful change through our words, our deeds and our culture. Every day, we want every employee to feel they belong to one General Motors team.

Benefits Overview

From day one, we’re looking out for your well-being–at work and at home–so you can focus on realizing your ambition. Learn how GM supports a rewarding career that rewards you personally by visiting Total Rewards resources.

Non-Discrimination and Equal Employment Opportunities (U.S.)

General Motors is committed to being a workplace that is not only free of unlawful discrimination, but one that genuinely fosters inclusion and belonging. We strongly believe that providing an inclusive workplace creates an environment in which our employees can thrive and develop better products for our customers.

All employment decisions are made on a non-discriminatory basis without regard to sex, race, color, national origin, citizenship status, religion, age, disability, pregnancy or maternity status, sexual orientation, gender identity, status as a veteran or protected veteran, or any other similarly protected status in accordance with federal, state and local laws.

Accommodations

General Motors offers opportunities to all job seekers including individuals with disabilities. If you need a reasonable accommodation to assist with your job search or application for employment, email us or call us at 1-800-865-7580. In your email, please include a description of the specific accommodation you are requesting as well as the job title and requisition number of the position for which you are applying.