Casting Process Simulation Intern: Yield & Scrap Reduction

Wisconsin Aluminum Foundry Master; Manitowoc (WI); On-site; USD 25,000 - 33,000; Full time

Job summary

Wisconsin Aluminum Foundry in Manitowoc, WI is seeking a Casting Process Simulation & Yield Improvement Intern to work on real production castings using MAGMA and SolidWorks. You’ll own a project from day one and present results to leadership.

You are pursuing a degree in mechanical, materials, metallurgical, or manufacturing engineering. The internship runs 12–14 weeks from May/June to August 2027, with a day shift 6 am–2:30 pm, paid.

Qualifications

• Pursuing a degree in mechanical, materials, metallurgical or manufacturing engineering.
• Understanding of solidification and gating principles.
• SolidWorks or similar 3D CAD experience.
• Problem-solving ability: you dig into root cause, not just symptoms.
• Attention to detail with data and measurements.
• Bonus: MAGMA, Flow-3D or other casting simulation experience, or foundry coursework.

Responsibilities

• Model solidification, filling and gating on target production jobs in MAGMA
• Redesign gating, risers and feeding in SolidWorks to improve yield and cut scrap
• Test your changes on the floor with process engineers and the foundry crew
• Track scrap, pour weight and finishing time before and after each change
• Find ways to reduce grinding, cut-off and other finishing time
• Present your results and recommendations to WAF leadership in August

Skills

SolidWorks

MAGMA

Flow-3D

Education

Mechanical, Materials, Metallurgical or Manufacturing Engineering (pursuing)

Tools

MAGMA

SolidWorks

Flow-3D

Job description

Wisconsin Aluminum Foundry in Manitowoc, WI is seeking a Casting Process Simulation & Yield Improvement Intern to work on real production castings using MAGMA and SolidWorks. You’ll own a project from day one and present results to leadership.

You are pursuing a degree in mechanical, materials, metallurgical, or manufacturing engineering. The internship runs 12–14 weeks from May/June to August 2027, with a day shift 6 am–2:30 pm, paid.