Foundry Process Engineer

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

Job DetailsJob Location: WAF - Manitowoc, WI 54220Position Type: Full Time

FOUNDRY PROCESS ENGINEER

Wisconsin Aluminum Foundry | Manitowoc, WI

You don't become a great casting engineer by staying behind a desk.

At Wisconsin Aluminum Foundry, you'll be where the real engineering happens – on the production floor, at the process, solving problems that don't have easy answers.

You will develop casting processes for new products, troubleshoot existing jobs, dig into scrap and customer complaints, work alongside production leaders and operators, and use tools like MAGMASOFT, DOE, metallurgy principles, and process analysis to make a good process better. You will actually see the result of your work.

Your process becomes the casting.

WHAT YOU'LL OWN

As a Foundry Process Engineer, you'll help develop robust, repeatable, error-proof casting processes from new job startup through production.

• Develop new casting processes and bring new projects from concept into production
• Solve problems at the source by investigating scrap, defects, and customer complaints
• Work directly with production supervisors and managers during new job launches and troublesome jobs
• Use MAGMASOFT simulation to troubleshoot and improve casting performance
• Apply Design of Experiments (DOE) and structured problem-solving methods
• Evaluate metallurgy, gating systems, casting design, and process parameters
• Partner with Engineering to review simulations and identify opportunities to improve the process
• Design, program, and troubleshoot pressure testing, qualification, and machining fixtures
• Spend meaningful time on the production floor working with the people who run the process

This isn't an engineering role where you hand off your work and move on.

You own the problem until it's solved.

THIS MIGHT BE YOU IF…

You probably enjoy the kind of problem that makes everyone else say:

"Why is this happening?"

And your first thought is:

"Let's figure it out."

You’ll fit well here if you:

• Have a Bachelor's degree in Engineering or a related field
• Have experience in an aluminum foundry, casting, or manufacturing environment
• Understand metallurgy, gating systems, casting design, and process development
• Are comfortable troubleshooting problems using data, technical analysis, and sound judgment
• Can make decisions when the answer isn't sitting in a textbook
• Communicate well with both engineers and people on the production floor
• Work well across Engineering, Operations, Quality, and leadership
• Know that the best solutions often come from getting close to the process

Experience with MAGMASOFT and SolidWorks is highly desirable.

WHY WAF?

For more than 115 years, Wisconsin Aluminum Foundry has been solving some of the toughest aluminum and copper-based casting challenges. Today, our engineers work with advanced casting technologies and integrated manufacturing capabilities to take products from engineering and prototyping through production.

But what makes WAF different isn't just the technology.

It's the people who refuse to settle for "good enough."

Here, your work doesn't disappear into a spreadsheet. You'll see your engineering decisions on the floor, in the process, and ultimately in the parts we ship to customers.

Stop looking for a job where you can make an impact.

Find one where you can see it.