Foundry Engineer

Weatherly Casting and Machine Co; Weatherly (Carbon County); On-site; USD 90,000 - 120,000; Full time

Job summary

Weatherly Casting and Machine Co is seeking an experienced Foundry Engineer to optimize gray and ductile iron casting processes on the production floor. You will develop tooling, gating and riser systems, and control documentation to improve quality and yield.

You will analyze process data, lead continuous improvement projects, and collaborate with quality, production and engineering teams to meet customer specifications and safety requirements.

Qualifications

• Hands-on foundry experience with gray iron and ductile iron.
• Bachelor’s degree in Engineering or related field or equivalent experience.
• 3–5 years of relevant foundry/manufacturing experience.
• Strong knowledge of metal casting, molding, gating and risering, tooling, and process control.
• ASNT Level II nondestructive testing certification for MPT and DPT.
• Experience with ISO quality systems, methods, procedures, and audits.
• Understanding of metallurgy, materials, and quality-control principles.
• Ability to analyze data, identify root causes, and develop corrective actions.
• Strong written and verbal communication across engineering, quality, and production.

Responsibilities

• Promote safety culture and ensure compliance with safety and environmental requirements.
• Develop and optimize foundry processes for gray and ductile iron castings.
• Design gating, riser systems and tooling using 3D modeling and casting simulation.
• Create and maintain process control documentation for molding, core making, and 3D sand printing.
• Analyze foundry data to identify root causes and drive continuous improvement.
• Participate in evaluation and implementation of new manufacturing technologies (3D scanning, 7-axis mold milling, 3D sand printing, automated grinding).
• Inspect and test products with metrology equipment, MPT, DPT, hardness and mechanical tests.
• Prepare technical reports and SOPs; lead internal ISO audits with cross-functional teams.

Skills

Foundry operations

Gray iron casting

Ductile iron casting

Process control

Quality systems

Root cause analysis

3D modeling

Casting simulation

Tooling design

Data analysis

Communication

Education

Bachelor's degree in Engineering

Equivalent combination of education and experience

Tools

Odyssey ERP

Casting simulation software

3D modeling software

Job description

We are seeking an experienced Foundry Engineer to support our quality, engineering, and continuous improvement initiatives. This position will focus on foundry processes, process controls, tooling, quality systems, and manufacturing improvements with the goal of producing high-quality castings and consistently meeting customer requirements.

REQUIRED: Candidates must have hands-on foundry experience working with both gray iron and ductile iron. Applicants without gray and ductile iron foundry experience will not be considered.

Key Responsibilities

• Promote a strong safety culture with a goal of zero harm and ensure compliance with all safety and environmental requirements.
• Develop and optimize foundry processes for gray and ductile iron castings.
• Design gating and riser systems to produce high-quality castings using 3D modeling and casting simulation software.
• Develop and design tooling, including patterns and core boxes, as well as 3D sand-printed cores and molds in accordance with gating and riser plans.
• Create and maintain process control documentation for molding, core making, and 3D sand printing.
• Analyze foundry process and quality data to identify root causes, reduce defects, and drive continuous improvement.
• Participate in the evaluation and implementation of emerging manufacturing technologies, including 3D scanning, 7-axis mold milling, 3D sand printing, and automated grinding systems.
• Inspect and test products and materials using metrology equipment, magnetic particle testing (MPT), dye penetrant testing (DPT), hardness testing, and mechanical testing.
• Test materials and document conformance to customer specifications and requirements.
• Develop quality documentation, Standard Operating Procedures (SOPs), and foundry process documentation.
• Participate as an active member of the internal ISO team and perform internal and external audits.
• Prepare technical reports by collecting, analyzing, and summarizing data and recommending corrective or improvement actions.
• Partner with department heads, supervisors, quality, and production teams to resolve manufacturing, quality, and process-control issues.
• Identify and implement opportunities for cost reduction, productivity improvement, process efficiency, and quality improvement.
• Manage and prioritize engineering projects and communicate project status and progress to appropriate stakeholders.
• Support the development and maintenance of manufacturing procedures, practices, standards, and controls.
• Maintain professional and technical knowledge of foundry technologies, processes, and industry best practices.
• Perform other duties as assigned.

Required Qualifications

• Hands-on foundry experience with BOTH gray iron and ductile iron is required.
• Bachelor’s degree in Engineering or a related engineering discipline, or an equivalent combination of education and relevant experience.
• 3–5 years of relevant foundry/manufacturing experience.
• Strong knowledge of metal casting and foundry processes, including molding, core making, gating and risering, tooling, and process control.
• ASNT Level II nondestructive testing certification for Magnetic Particle Testing (MPT) and Dye Penetrant Testing (DPT).
• Experience working with ISO quality systems, manufacturing methods, procedures, and audit requirements.
• Understanding of metallurgy, material properties, raw materials, production processes, and quality‑control principles.
• Ability to analyze manufacturing and quality data, identify root causes, and develop effective corrective and preventive actions.
• Strong critical‑thinking and complex problem‑solving skills.
• Ability to develop process documentation, SOPs, technical reports, and presentations.
• Strong written and verbal communication skills with the ability to work effectively across engineering, quality, production, supervision, and management.
• Working knowledge of plant equipment and manufacturing processes.
• Proficiency with standard computer applications, including spreadsheets, word processing, databases, statistical software, and related engineering tools.

Preferred Qualifications

• Experience with Odyssey ERP.
• Experience with casting simulation and 3D modeling software.
• Experience with advanced foundry technologies such as 3D sand printing, 3D scanning, automated grinding, and mold milling.
• Experience participating in or leading continuous improvement, cost reduction, and process optimization initiatives.

What We're Looking For

The ideal candidate is a hands‑on foundry engineer who understands the challenges of producing consistent, high-quality gray and ductile iron castings. This individual will be comfortable working on the production floor, analyzing process and quality data, troubleshooting casting issues, developing tooling and processes, and collaborating across departments to drive measurable improvements in safety, quality, productivity, and cost.