Casting Process Engineer - From Concept to Production

Wisconsin Aluminum Foundry Master; Manitowoc (WI); On-site; USD 90,000 - 120,000; Full time

Job summary

Wisconsin Aluminum Foundry in Manitowoc, WI is seeking a Foundry Process Engineer to develop robust casting processes from startup through production. You will work on the production floor with operators and engineers, applying MAGMASOFT, DOE, metallurgy principles and process analysis to improve processes and outcomes.

Your role includes designing new processes, solving scrap and defect issues, reviewing simulations, and hands-on fixture testing while staying close to the production flow.

Qualifications

• Bachelor's degree in Engineering or a related field.
• Experience in an aluminum foundry, casting, or manufacturing environment.
• Understanding metallurgy, gating systems, casting design, and process development.
• Able to troubleshoot problems using data, technical analysis, and sound judgment.
• Communicate well with engineers and people on the production floor.
• Experience with MAGMASOFT and SolidWorks is highly desirable.

Responsibilities

• Develop new casting processes and bring projects from concept to production.
• Solve problems at the source by investigating scrap, defects, and customer complaints.
• Work with production supervisors and managers during new job launches.
• Use MAGMASOFT simulation to troubleshoot and improve casting performance.
• Apply DOE and structured problem-solving methods.
• Evaluate metallurgy, gating, casting design, and process parameters.
• Partner with Engineering to review simulations and identify improvement opportunities.
• Design, program, and troubleshoot testing fixtures and machining fixtures.
• Spend meaningful time on the production floor with operators.

Skills

Problem solving

Data analysis

DOE

MAGMASOFT

Metallurgy

Process analysis

Communication

Education

Bachelor's degree in Engineering or related field

Tools

MAGMASOFT

SolidWorks

Job description

Wisconsin Aluminum Foundry in Manitowoc, WI is seeking a Foundry Process Engineer to develop robust casting processes from startup through production. You will work on the production floor with operators and engineers, applying MAGMASOFT, DOE, metallurgy principles and process analysis to improve processes and outcomes.

Your role includes designing new processes, solving scrap and defect issues, reviewing simulations, and hands-on fixture testing while staying close to the production flow.