Simulation Foundry Engineer

Le Sueur Incorporated; Le Sueur (MN); On-site; USD 85,000 - 115,000; Full time

Job summary

Le Sueur Incorporated is seeking a simulation engineer to coordinate mold flow and solidification analyses, update 3D CAD models, and perform CAE analyses to support product launches and improve performance.

The role supports tooling and design for gating systems, uses Creo/SolidWorks/SpaceClaim/OnShape for mold designs, and utilizes Magmasoft/ProCast/EKK for mold flow simulations to predict defects and solidification patterns. Travel up to 10% across the US, Canada, and Mexico.

Qualifications

• Bachelor's degree in Mechanical or Materials Engineering or related field.
• 5 years of progressive post-bachelor's experience as a simulation engineer in a foundry environment.
• 5 years of experience in mold flow and solidification analysis software.
• 1 year of experience in CAD software such as SolidWorks.
• 3 years of hands-on experience in casting and simulation.

Responsibilities

• Coordinate and develop moldflow and solidification analyses; create/update 3D CAD models; perform CAE analysis and participate in Product Launch to improve simulations and performance.
• Support tooling and design in development of optimized gating systems for iron, aluminum and steel castings.
• Use CAD tools (Creo, SolidWorks, SpaceClaim, OnShape) to assist mold designs for tool fabrication.
• Use Magmasoft, ProCast or EKK to simulate mold flow, predict defects, and analyze solidification patterns.
• Provide engineering input during NPI meetings to optimize casing processes; communicate with customers and internal teams to ensure satisfaction.
• Liaise between customers and manufacturing teams to resolve mold flow and solidification questions.
• Conduct R&D using mold flow/solidification software to deliver accurate results timely.
• Validate designs/simulations against actual casting results; engineer prototype/production tools for various casting processes.
• Optimize/modify customer CAD files for molding/casting processes.

Skills

Mold flow analysis

Solidification analysis

CAE analysis

Cross-functional collaboration

Willingness to travel

Education

Bachelor's degree in Mechanical or Materials Engineering

Tools

Creo

SolidWorks

SpaceClaim

OnShape

Magmasoft

ProCAST

EKK

Job description

Responsible for coordinating and developing moldflow and solidification analysis; creating and updating 3D CAD models; performing CAE analysis and participate in the Product Launch process to improve simulation results and performance.

• Support the tooling and design department in the development of optimized gating systems for iron, aluminum and steel castings.
• Use CAD technology such as Creo, SolidWorks, SpaceClaim or OnShape to assist with mold designs for tool fabrication.
• Use software technology for simulation of the foundry processes, like Magmasoft, ProCast or EKK to assist with the mold flow simulation, defect predictions and solidification patterns.
• Provide technical input during the new product start-up meetings to establish the most effective and efficient casting process to meet or exceed the quality and cost goals, as quoted.
• Communicate with customers, and internal production areas using mold flow and solidification analysis, ensuring customer satisfaction.
• Liaise between the customer and manufacturing team to resolve mold flow and solidification analysis questions.
• Conduct research and development utilizing mold flow and solidification analysis software to develop accurate analysis results in a timely manner.
• Validate designs and simulations against actual casting results to continually improve the process.
• Engineer and design prototype & production tools for sand casting, investment casting, and other processes.
• Optimize/modify customer CAD files for molding and castings processes.
• Adhere to the rules and conventions established by the Pattern Work Instruction.
• Provide engineering support to all molding operations.

10% travel within the United States, Canada and Mexico

Job Requirements:

Bachelor's degree in Mechanical Engineering, Materials engineering or related engineering field, and ( 5) Five years of progressive post bachelor's experience as a simulation engineer, in a foundry environment.

Also requires the following:

• 5 years of experience in mold flow and solidification analysis software
• 1 year of experience in CAD Software such as Solid Works
• 5 years of experience using Magmasoft, Procast or EKK
• 3 years of hands-on experience in casting and simulation

Also requires certificates of training to use the software: