Process Engineer

Sanford Barrows Group; New Britain (CT); On-site; USD 85,000 - 125,000; Full time

Job summary

Sanford Barrows Group in Connecticut is seeking a Casting Engineer to support development, optimization, and continuous improvement of aluminum investment and permanent mold casting processes. You will collaborate with production, quality, tooling, machining, and customer-facing teams to ensure cast components meet demanding quality, performance, cost, and delivery requirements.

The role involves new product introduction, process development, yield improvement, defect reduction, and

Qualifications

• Bachelor's degree in Metallurgical, Materials, Mechanical, Manufacturing, Industrial Engineering, or related discipline.
• 3–7 years of casting engineering or closely related manufacturing experience.
• Hands-on experience with aluminum casting.
• Experience supporting aerospace or other highly regulated manufacturing environments.
• Ability to interpret engineering drawings, blueprints, and GD&T.

Responsibilities

• Develop and optimize manufacturing processes for aluminum casting.
• Design and validate gating, riser, and feeding systems using sound engineering principles.
• Establish repeatable processes that maximize yield, reduce scrap, and improve product quality.
• Develop process parameters, manufacturing instructions, and supporting engineering documentation.
• Provide hands-on technical support for casting and production-related issues.
• Lead engineering activities from customer drawing review through production launch.
• Review drawings and technical specifications for manufacturability.
• Coordinate tooling requirements with internal toolmakers and external suppliers.
• Support first article inspections, process validation, and production readiness.
• Partner with customers and internal stakeholders throughout the launch process.
• Lead root-cause investigations related to casting defects and process variation.
• Utilize problem-solving tools such as 8D, 5 Whys, fishbone diagrams, PFMEA, and DOE.

Skills

Aluminum casting

Root-cause analysis

GD&T interpretation

Problem solving

Project management

Education

Bachelor's degree in Metallurgical, Materials, Mechanical, Manufacturing, Industrial Engineering

Tools

SolidWorks

AutoCAD

Job description

A well-established aerospace manufacturer is seeking a Casting Engineer to support the development, optimization, and continuous improvement of aluminum investment and permanent mold casting processes.

This individual will collaborate closely with production, quality, tooling, machining, and customer-facing teams to ensure cast components meet demanding quality, performance, cost, and delivery requirements. The role will have significant involvement in new product introduction, process development, yield improvement, defect reduction, and overall manufacturing excellence

.
Key Responsibiliti

• esDevelop and optimize manufacturing processes for new and existing aluminum casting
• s.Design and validate gating, riser, and feeding systems using sound engineering principle
• s.Establish repeatable processes that maximize yield, reduce scrap, and improve product qualit
• y.Develop process parameters, manufacturing instructions, and supporting engineering documentatio
• n.Provide hands-on technical support for casting and production-related issue
• s.Lead engineering activities from customer drawing review through production launc
• h.Review drawings and technical specifications for manufacturabilit
• y.Coordinate tooling requirements with internal toolmakers and external supplier
• s.Support first article inspections, process validation, and production readines
• s.Partner with customers and internal stakeholders throughout the launch proces
• s.Analyze manufacturing data to identify trends and improvement opportunitie
• s.Lead root-cause investigations related to casting defects and process variatio
• n.Utilize problem-solving tools and methodologies such as 8D, 5 Whys, fishbone diagrams, PFMEA, and design of experiment
• s.Implement corrective and preventive action
• s.Drive measurable reductions in scrap, rework, defects, and manufacturing cycle tim
• e.Support Lean Manufacturing and Six Sigma initiative
• s.Support compliance with AS9100, customer specifications, and applicable NADCAP requirement
• s.Participate in internal, customer, and regulatory audit
• s.Maintain accurate, current, and properly controlled engineering documentatio
• n.Support the development and maintenance of control plans, process flows, and PFMEA
• s.Collaborate with production, quality, manufacturing engineering, tooling, machining, purchasing, and program managemen
• t.Assist operators and supervisors in resolving manufacturing challenge
• s.Participate in technical discussions, process reviews, and audits with aerospace customer
• s.Prepare timely and accurate responses to customer technical inquirie

s.
Qualificati

• onsBachelor’s degree in Metallurgical, Materials, Mechanical, Manufacturing, Industrial Engineering, or a related engineering discipli
• ne.Approximately 3–7 years of casting engineering or closely related manufacturing experien
• ce.Hands-on experience with aluminum casting process
• es.Experience supporting aerospace or another highly regulated manufacturing environme
• nt.Strong understanding of casting defects, troubleshooting, and root-cause analys
• is.Ability to interpret engineering drawings, blueprints, and GD&
• ;T.Strong analytical, organizational, project-management, and communication skil

ls.
Preferred Experi

• nce.Permanent mold casting experie
• nce.Knowledge of CNC machining and downstream manufacturing proces
• ses.Experience with aerospace quality systems and customer requireme
• nts.Familiarity with SolidWorks, AutoCAD, or comparable CAD softw
• are.Six Sigma Green Belt, Black Belt, or Lean Manufacturing certificat