Lead Die Casting Process Engineer – Launch & Optimize

General Motors; Bedford (IN); On-site; USD 90,000 - 120,000; Full time

Job summary

General Motors is seeking a Die Casting Process Engineer to support development and launch of high pressure die casting programs. You will work with product and equipment engineers on tooling design, evaluate simulation results, and perform process setup on the plant floor.

The role requires hands-on experience with casting shop activities, strong knowledge of PFMEA and process control plans, and collaboration with cross-functional teams to ensure successful program launches.

Qualifications

• Foundry experience and ability to apply casting concepts in manufacturing.
• Knowledge of high pressure die casting or related tooling/quality
• Understanding of aluminum chemistry, heat treatment, metallurgical processes

Responsibilities

• Support launch validations, build plans, PPAP and related procedures.
• Assist testing and installation of equipment, tooling, and technologies on and off site.
• Lead analysis of casting defects and present findings to cross-functional teams.
• Develop process documentation including PFMEA, PCP, and process control plans.
• Analyze first time quality data and optimize processes using DOE and statistical tools.
• Perform non-destructive testing and process start up on the plant floor.

Skills

Die casting knowledge

Manufacturing concepts

DOE and statistics

Mechanical concepts

Education

BS in Engineering or Metallurgy

Tools

Magma

Flow 3D

Job description

General Motors is seeking a Die Casting Process Engineer to support development and launch of high pressure die casting programs. You will work with product and equipment engineers on tooling design, evaluate simulation results, and perform process setup on the plant floor.

The role requires hands-on experience with casting shop activities, strong knowledge of PFMEA and process control plans, and collaboration with cross-functional teams to ensure successful program launches.