Senior Process Engineer - Casting

General Motors; Warren (MI); On-site; USD 90,000 - 130,000; Full time

Job summary

General Motors seeks a Senior Process Engineer – Casting to lead development and execution of casting manufacturing processes, tooling, and alternatives for production launches. The role emphasizes technical rigor, process validation, and cross-functional collaboration across design, tooling and quality teams.

The candidate will analyze defects, develop process documentation, and apply DOE and flow simulations to optimize quality and efficiency on site. Strong casting knowledge is essential.

Qualifications

• 3+ years of professional experience in a manufacturing environment.
• Demonstrated knowledge of foundry processes and applying casting concepts in manufacturing.
• 2+ years in Low Pressure Die Casting, Precision Sand, Semi Permanent Mold or similar.
• Knowledge of process engineering procedures and disciplines.
• Basic knowledge of 3D design software and metallurgy.

Responsibilities

• Work individually on programs yet collaborate with Launch Team, QC, Design, Tooling, and support groups.
• Apply foundry concepts in a manufacturing environment and support manufacturing validations.
• Lead testing of equipment, tooling and technologies on and off site.
• Develop process documentation, flow diagrams, PCP, PFMEA, and related technical docs.
• Analyze first time quality data and optimize processes using DOE and statistical tools.
• Perform non-destructive testing and casting investigations.
• On-site hands-on work on the shop floor with an understanding of casting activity.

Skills

Foundry knowledge

Casting concepts

DOE/Statistical tools

Shop floor hands-on

Mechanical design concepts

Manufacturing environment

Education

BS in engineering or related

Tools

Magma

Flow 3D

NX

CATIA

Job description

Job Description

At General Motors, our product teams are redefining mobility. Through a human-centered design process, we create vehicles and experiences that are designed not just to be seen, but to be felt. We’re turning today’s impossible into tomorrow’s standard —from breakthrough hardware and battery systems to intuitive design, intelligent software, and next-generation safety and entertainment features.

Every day, our products move millions of people as we aim to make driving safer, smarter, and more connected, shaping the future of transportation on a global scale.

SENIOR PROCESS ENGINEER – CASTING

The Role

The Launch Process Engineering Team excels in the development, testing, implementation and execution of new casting programs, platforms and technology. This group is unique in that by working with and across multiple levels of the GM technical groups, vendors and suppliers, the complex problems of casting projects are developed into controlled manufacturing processes.

The specific purpose of this position is to perform casting manufacturing projects by following a systematic engineering process of evaluation, development, validations, technology transfer leading into and supporting the production launch and processing. Specifically responsible and directly involved in the development of manufacturing processes, equipment, tooling and alternatives, sequences, operations, utilizations for the production of castings.

What You'll Do

• Ability to work individually on specific programs yet collaboratively with Launch Team, QC, Design, Tooling, and other support groups
• Demonstrate technical knowledge of foundry processes and ability to apply concepts in a manufacturing environment
• Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering procedures
• Support testing and installations of equipment, tooling and technologies both on and off site
• Lead, support and present the analysis of casting defects
• Assist in process, tooling and equipment testing, troubleshooting and implementations
• Develop process documentation, Process flow diagrams, PCP, PFMEA, TIS, and related technical documents as necessary for a program launch
• Analyze first time quality data and optimize processes using DOE, Red X, and related statistical tools
• Perform both Non and destructive testing procedures for casting investigation and analysis (leak testing, x ray, CT, thermal, lab specimen prep, chemistry, density, mechanical, etc)
• On site work, working on shop floor, hands on equipment, understanding of casting shop activity.

Your Skills And Abilities (required Qualifications)

• 3+ years of professional experience in a manufacturing environment
• Demonstrated knowledge of foundry processes and ability to apply casting concepts in a manufacturing environment
• 2+ years of professional experience in Low Pressure Die Casting, Precision Sand, Semi Permanent Mold or similar, tooling, process, quality, or project management experience.
• Knowledge of process engineering procedures and disciplines
• Basic knowledge of Magma, Flow 3D, simulation software
• Basic knowledge of NX or Catia or any 3D design software
• Effective and functional knowledge of aluminum chemistry, heat treat, metallurgical processes
• Demonstrated understanding of mechanical concepts involving machine design, process equipment, tooling, and secondary post processing
• BS degree (engineering, metallurgical, computer science) or equivalent experience is required

What Will Give You a Competitive Advantage (preferred Qualifications)

• Training in aluminum metallurgy
• Prior experience in Low Pressure Die Casting, Precision Sand or Semi Permanent Mold
• Prior experience in injection molds
• Prior experience in castings or Giga/Structural castings
• Training in flow simulations ( Magma, Flow 3d)
• Training in 3D design software
• Mechanical properties testing and procedures
• Background in Aluminum chemistry is encouraged
• Training in Problem solving

GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc). This role is categorized as onsite. This means the selected candidate is expected to report to a specific location on a full-time basis. The selected candidate will be required to travel at least 50% or more on a frequent basis. This job is not eligible for relocation benefits. Any relocation costs would be the responsibility of the selected candidate.

About GM

Our vision is a world with Zero Crashes, Zero Emissions and Zero Congestion and we embrace the responsibility to lead the change that will make our world better, safer and more equitable for all.

Why Join Us

We believe we all must make a choice every day – individually and collectively – to drive meaningful change through our words, our deeds and our culture. Every day, we want every employee to feel they belong to one General Motors team.

Benefits Overview

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We encourage interested candidates to review the key responsibilities and qualifications for each role and apply for any positions that match their skills and capabilities. Applicants in the recruitment process may be required, where applicable, to successfully complete a role-related assessment(s) and/or a pre-employment screening prior to beginning employment. To learn more, visit How we Hire.

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