Senior Casting Engineer (Onsite)

RTX; Rockford (IL); On-site; USD 87,000 - 165,000; Full time

Job summary

RTX Rockford, IL seeks a Senior Casting Engineer to support aerospace castings for drive generators, motors, and ram air turbines. You will collaborate with design and manufacturing engineers and suppliers to meet cost, weight, and reliability targets for industry-leading components.

Responsibilities include manufacturability reviews of complex geometry sand castings, tooling design and evaluation, and process development with plant sites and suppliers, plus standard-work creation and

Qualifications

• Bachelor's or higher STEM degree with 5+ years of relevant experience, or an advanced degree with 3+ years.
• Experience with sand casting and complex geometry aerospace components.
• Ability to design and evaluate tooling for cast components (patterns, cores, gating).

Responsibilities

• Oversee manufacturability of components via sand casting with a focus on housings.
• Review engineering drawings for manufacturability and feasibility.
• Design and evaluate tooling for casted components to assure producibility and cost.
• Develop and optimize manufacturing processes with plant sites and suppliers.
• Create standardized work procedures for production consistency.
• Analyze costs with sites and suppliers to reduce standard costs.
• Identify root causes of production issues and implement corrective actions.
• Travel 25-50%.

Skills

Multidisciplinary teamwork

Root cause analysis

Manufacturing process development

Cost reduction

Problem solving

Education

STEM degree + 5 years experience

Advanced degree + 3 years experience

Tools

Casting tooling design

Casting simulation

Job description

Date Posted:

2026-07-09

Country:

United States of America

Location:

US-IL-ROCKFORD-P6 ~ 4747 Harrison Ave ~ 4747 HARRISON AVE-P6

Position Role Type:

Onsite

U.S. Citizen, U.S. Person, or Immigration Status Requirements:

U.S. citizenship is required, as only U.S. citizens are authorized to access information under this program/contract.

Security Clearance Type:

None/Not Required

Security Clearance Status:

Not Required

We’reseeking aSeniorCastingEngineer to support our Electric Systems Power Generation department. In this role,you’llbesupporting the design andmanufacturingof castings used to produce productslike Integrated Drive Generators, Variable Frequency Generators, motors, and ram air turbines.

As aSeniorCastingEngineer,you’llcollaborate closely with design engineers, manufacturing engineers, and suppliers to ensure our mechanical and electromagnetic equipment meet rigorous cost, weight, and reliability standards.You will develop and drive innovative solutions that are necessary to support our supplier and plant sites as we produce and deliver the industry leading products that power the aerospace industry.

What You Will Do

• Support Aerospace Component Production: Oversee the manufacturability ofvarious components with a focus on housings and other components that are produced via complex geometry sand casting practices.

• Engineering Drawing Review: Conduct thorough evaluations of engineering drawings to ensure designs are bothfeasibleandoptimizedfor manufacturability.

• CastingTooling Design and Evaluation: Design and review tooling forproducing casted components, focusing on producibility, quality, and cost.

• Manufacturing Process Development and Optimization: Collaborate with plant sites and suppliers to develop and refine manufacturing processes, troubleshoot issues, and drive continuous improvement.

• Standard Work Development: Create and implement standardized work procedures to ensure consistency, quality, and efficiency in production processes.

• Cost Reduction Initiatives: Work closely with plant sitesand suppliersto analyze and reduce standard costs, implementing cost-saving measures without compromising quality.

• Production Support and Problem Resolution:Identifyroot causes of production issues and implement corrective actions tomaintainsmooth and efficient operations.

• Travel 25-50%

What You Will Learn

• You will learn how to lead the production ofcutting-edgeaerospace components, including Integrated Drive Generators and Variable Frequency Generators, making a tangible difference in advanced aerospace systems.

• You will gain hands‑on experience with complex electromagnetic systems, mastering skills from design and manufacturability to tooling and production optimization.

Qualifications You Must Have

• Typically requires a degree in Science, Technology, Engineering or Mathematics (STEM) and minimum5years prior relevant experienceor an Advanced Degree in a related field and minimum3years of experience

Qualifications We Prefer

• Experience designing, producing, or supporting complex-geometry sand-cast components, particularly for aerospace or similar high-tech industries.

• Proficiencyin designing and evaluating tooling for cast components, including patterns, cores, gating, and casting simulation.

• Experience in developing,optimizing, and troubleshooting manufacturing processes, witha track recordof collaboration with plant sites and suppliers.

• Experience with other processes that may be used in lieu of castingsuch as, traditional machininghogoutsand additive manufacturing via powder bed fusion, material jetting, directed energy deposition, etc.

• Proven ability to analyze and reduce standard costs whilemaintaininghigh quality, with experience in cost management and efficiency improvements.

• Skilledinidentifyingroot causes of production issues and implementing effective corrective actions to ensure smooth and efficient operations.

• Ability to review and interpret engineering drawings to ensure designs arefeasibleandoptimizedfor manufacturability.

• Excellent interpersonal skills with a demonstrated ability to work effectively within multidisciplinary teams andestablishstrong working relationships.

What We Offer

Some of our competitive benefits package includes:

• Medical, dental, and visioninsurance

• Three weeks of vacation for newly hiredemployees

• Generous 401(k) plan that includes employer matching funds and separate employer retirement contribution, including a Lifetime Income Strategy option

• Tuition reimbursement program

• Student Loan Repayment Program

• Life insurance and disability coverage

• Optional coverages you canbuy:pet insurance, home and auto insurance,additionallife and accident insurance,critical illnessinsurance, group legal, ID theft protection

• Birth, adoption, parental leave benefits

• Ovia Health, fertility, and family planning

• Adoption Assistance

• Autism Benefit

• Employee Assistance Plan, including up to 10 free counseling sessions

• Healthy You Incentives, wellness rewards program

• Doctor on Demand, virtual doctor visits

• Bright Horizons,childand elder care services

• Teladoc Medical Experts, second opinion program

• And more!

We make modern flight possible for millions of travelers and our military every second. Our major product lines areon-boardvirtually everyaircraftflying. Be it keeping passengers safe with our emergency power generation systems or creating a positive in-flight experience through reliable cabin pressure controls and quieter engines, Power & Controls focuses on delivering a best-in-class experience to our customers. We hire the top people in the industry. Their ideas drive our performance, and their integrity keeps our customers happy. Join us as we take flight!

Employees who are working in Onsite roles will work primarily onsite. This includes all production and maintenance employees, as they are essential to the development of our products.

At Collins, the paths we pave together lead to limitlesspossibility. And the bonds we form – with our customers and with each other – propel us all higher,again and again.

As part of our commitment to maintaining a secure hiring process, candidates may be asked to attendselect steps of the interview process in‑person at one of our office locations, regardless of whether the role is designated as on‑site, hybrid or remote.

The salary range for this role is 86,800 USD - 165,200 USD. The salary range provided is a good faith estimate representative of all experience levels. RTX considers several factors when extending an offer, including but not limited to, the role, function and associated responsibilities, a candidate’s work experience, location, education/training, and key skills.

Hired applicants may be eligible for benefits, including but not limited to, medical, dental, vision, life insurance, short-term disability, long-term disability, 401(k) match, flexible spending accounts, flexible work schedules, employee assistance program, Employee Scholar Program, parental leave, paid time off, and holidays. Specific benefits are dependent on the specific business unit as well as whether or not the position is covered by a collective-bargaining agreement.

Hired applicants may be eligible for annual short-term and/or long-term incentive compensation programs depending on the level of the position and whether or not it is covered by a collective-bargaining agreement. Payments under these annual programs are not guaranteed and are dependent upon a variety of factors including, but not limited to, individual performance, business unit performance, and/or the company’s performance.

This role is a U.S.-based role. If the successful candidate resides in a U.S. territory, the appropriate pay structure and benefits will apply.

RTX anticipates the application window closing approximately 40 days from the date the notice was posted. However, factors such as candidate flow and business necessity may require RTX to shorten or extend the application window.

RTX is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability or veteran status, or any other applicable state or federal protected class. RTX provides affirmative action in employment for qualified Individuals with a Disability and Protected Veterans in compliance with Section 503 of the Rehabilitation Act and the Vietnam Era Veterans’ Readjustment Assistance Act.

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