Senior Foundry Engineer

Success Matcher Recruitment; Billerica (MA); On-site; USD 120,000 - 190,000; Full time

Job summary

Our client in the U.S. is building a next-generation investment casting operation focused on nickel-based superalloys for aerospace and defense.

Reporting to the CTO, the Senior Foundry Engineer will drive the architecture of a new automated foundry, turning artisanal casting into repeatable, high-tech production. You will own processes from melt to solidification, source and commission VIM and inspection tools, collaborate with shell engineering and software teams, and help design a 60,000 sq

Qualifications

• 5+ years in investment casting environment.
• Experience with nickel superalloy casting.
• Aerospace/defense industry knowledge is a plus.

Responsibilities

• Lead development of nickel superalloy investment casting processes.
• Source and commission foundry equipment including VIM.
• Collaborate with shell engineering, metallurgy and software teams to encode foundry DNA.
• Scale-up and design a 60,000 sq ft production facility.
• Drive processes toward AS9100 certification for flight-critical hardware.

Skills

Foundry expertise

Nickel superalloy casting

Process ownership

Cross-functional collaboration

Tools

VIM equipment

Job description

Our client is building the future of American industrial power by developing fully automated investment casting foundries. In an era where demand for precision metal castings is skyrocketing but domestic supply chains are failing, our client is stepping in to restore critical manufacturing capabilities for the U.S. Aerospace and Defense sectors.

Backed by industry titans like RTX Group (Raytheon/Pratt & Whitney) and Lockheed Martin, our client is a well-capitalized startup already shipping parts and moving rapidly toward AS9100 certification. We are looking for a Senior Foundry Engineer to serve as the foundational expert on an elite team, owning the nickel superalloy casting process from the ground up.

The Role

Reporting directly to the CTO, you will be the first true foundry expert in the building. This isn't a desk job where you monitor spreadsheets; you will be the architect of a new production facility. You will bring the institutional knowledge necessary to turn artisanal casting into repeatable, high-tech engineering.

What You Will Be Doing:

Process Ownership: Lead the development of nickel superalloy investment casting processes—from melt practice and shell interaction to solidification and defect elimination.

Equipment Commissioning: Source and commission critical foundry equipment, including vacuum induction melters (VIM) and downstream inspection tooling.

Cross-Functional Collaboration: Partner with shell engineering and metallurgy teams, while working with software engineers to encode foundry "DNA" into a proprietary AI-driven Foundry OS.

Scale-Up & Design: Help the CEO and CTO design a next-generation 60,000 sq. ft. production facility, defining the workflow for the ideal automated foundry.

Quality & Compliance: Drive processes toward AS9100 certification for flight-critical hardware used by major defense primes.

Who You Are

Experienced: You have 5+ years of hands-on experience in an investment casting environment (e.g., PCC, Howmet, GE Aerospace, etc.).

Technical: You have "poured metal" and lived on the foundry floor. You understand the nuances of high-temperature alloys and what it takes to hit aerospace specifications.

Mission-Driven: You are energized by the prospect of reviving a critical industry and contributing to national security.

Builder Mentality: You thrive in a fast-moving startup environment where you have the autonomy to make decisions without legacy bureaucracy.