Permanent Mold 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 Permanent Mold Process Engineer. You will develop robust, repeatable permanent mold processes from new job launch through full production, including tilt-pour and low-pressure methods.

You’ll work with MAGMASOFT for simulation, coordinate with toolroom, operators, QA and engineering, and travel to solve mold-related issues on the floor. A mechanical engineering degree and permanent mold experience are preferred.

Qualifications

• Bachelor's degree in Engineering or related field.
• Experience in permanent mold or die casting (aluminum preferred).
• Understand how mold temperature, coatings and gating drive solidification and casting quality.
• Knowledge of aluminum casting alloys and heat treatment basics.
• Troubleshoot with data, technical analysis and sound judgment.

Responsibilities

• Launch new permanent mold jobs from tooling design review through PPAP and steady production.
• Set and balance mold thermal management from die temperatures, water and air cooling, thermocouple placement, cycle time.
• Design and refine gating, risering and fill for gravity, tilt-pour and low-pressure molds.
• Use MAGMASOFT to predict fill and solidification before steel is cut, then prove it on the floor.
• Own die coating practice, mold preheat, and core integration for semi-permanent mold jobs.
• Attack porosity, shrink, cold shuts and misruns at the root using DOE and structured problem solving.
• Partner with our in-house toolroom on new molds, modifications and mold life.
• Work side by side with operators, supervisors, Quality and Engineering on troublesome jobs.
• Spend real time at the machine, that's where permanent mold problems get solved.

Skills

Permanent Mold Experience

DOE analysis

Communication

Education

Bachelor's degree in Engineering

Tools

MAGMASOFT

SolidWorks

Job description

Job Details: Job Location: WAF - Manitowoc, WI 54220, Position Type: Full Time, PERMANENT MOLD PROCESS ENGINEER

Wisconsin Aluminum Foundry | Manitowoc, WI

The mold is permanent. The problems aren't.

In permanent mold, the steel remembers everything. Every degree of die temperature, every coating pass, every second of cycle time. Get it right and you pour the same precise casting thousands of times. Get it wrong and the scrap tells you fast.

At Wisconsin Aluminum Foundry, you'll own that process. You'll work on static, tilt-pour and low-pressure permanent mold, including one of the largest permanent mold machines in the country, during the biggest permanent mold expansion in our history.

Your process becomes the casting. Thousands of times over.

WHAT YOU'LL OWN

As a Permanent Mold Process Engineer, you'll develop robust, repeatable, error-proof permanent mold processes from new job launch through full production.

• Launch new permanent mold jobs from tooling design review through PPAP and steady production
• Set and balance mold thermal management from die temperatures, water and air cooling, thermocouple placement, cycle time
• Design and refine gating, risering and fill for gravity, tilt-pour and low-pressure molds
• Use MAGMASOFT to predict fill and solidification before steel is cut, then prove it on the floor
• Own die coating practice, mold preheat, and core integration for semi-permanent mold jobs
• Attack porosity, shrink, cold shuts and misruns at the root using DOE and structured problem solving
• Partner with our in-house toolroom on new molds, modifications and mold life
• Work side by side with operators, supervisors, Quality and Engineering on troublesome jobs
• Spend real time at the machine, that's where permanent mold problems get solved

THIS MIGHT BE YOU IF…

You look at a casting with porosity in the same spot every shift and think:

"That's a thermal problem. Let's find it."

You'll fit well here if you:

• Have a Bachelor's degree in Engineering (Mechanical, Materials, Metallurgical, Manufacturing) or a related field
• Have experience in permanent mold, low-pressure permanent mold, or die casting (aluminum preferred)
• Understand how mold temperature, coatings and gating drive solidification and casting quality
• Know aluminum casting alloys and heat treatment basics
• Troubleshoot with data, technical analysis and sound judgment
• Can make the call when the answer isn't in a textbook
• Communicate well with engineers, toolmakers and the people running the machines

Experience with MAGMASOFT and SolidWorks is highly desirable. Die casting engineers ready to move into permanent mold: we want to talk to you.

WHY WAF?

For more than 115 years, Wisconsin Aluminum Foundry has been solving some of the toughest aluminum and copper-based casting challenges. We're investing heavily in permanent mold. From new capacity, new equipment, and a full in-house toolroom, we take parts from engineering and prototyping through precision 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 in the mold, on the machine, and in every part we ship.

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

Find one where you can repeat it.

Qualifications: