Tool Design Engineer

MacLean Power Systems; Alabaster (AL); On-site; USD 85,000 - 110,000; Full time

Job summary

MacLean Power Systems seeks a foundry tooling engineer to design and develop tooling for a sand casting operation, focusing on patterns, match plates, cope and drag plates, and core boxes. This role uses MAGMA casting simulations to model mold filling and solidification, guiding tooling improvements to enhance yield and throughput.

The candidate will collaborate with Foundry, South Floor, Tool Room, and CNC teams, create 3D models and production drawings, and ensure tooling is machined

Qualifications

• Bachelor's degree in Mechanical, Manufacturing, or Metallurgical Engineering or equivalent.
• 3+ years of tooling or pattern design experience for a sand casting foundry.
• Hands-on MAGMA MAGMASOFT or similar casting simulation software experience.
• Proficiency in 3D CAD software (SolidWorks or similar) and creating production drawings.
• Working knowledge of CNC machining and design for manufacturability.
• Ability to perform work under minimal supervision and escalate only complex issues.

Responsibilities

• Design and develop foundry tooling for sand casting, including patterns, match plates, cope and drag plates, core boxes, and related fixtures.
• Run MAGMA casting simulations to predict defects and guide tooling improvements.
• Design and optimize gating, runner, riser, and feeding systems and validate via simulation and trials.
• Lead redesign of legacy pattern plates to improve yield and plan/tooling changeovers.
• Create 3D models and production drawings; coordinate with CNC to ensure accurate tooling manufacture.
• Maintain tooling records and documentation; ensure 5S and safety compliance.

Skills

MAGMA casting simulations

3D modeling

GD&T

Root cause analysis

Project management

Interpersonal communication

Education

Bachelor's degree in Mechanical/Manufacturing/Metallurgical Engineering

Tools

MAGMASOFT

SolidWorks

CNC programming

Job description

Job Summary

Designs and develops foundry tooling for a sand casting operation, with a focus on patterns, pattern plates, and core boxes. This role uses MAGMA casting simulation to model mold filling and solidification, and designs new plates to replace legacy tooling that contributes to mold shift and poor yield. The engineer works with the Foundry, South Floor, Tool Room, and CNC teams to improve casting quality, yield, and throughput.

Job Duties

• Design and develop foundry tooling for sand casting, including patterns, match plates, cope and drag plates, core boxes, and related fixtures
• Run MAGMA casting process simulations of mold filling, solidification, and cooling to predict and prevent defects such as shrinkage, porosity, misruns, and cold shuts
• Design and optimize gating, runner, riser, and feeding systems, and validate them through simulation and trial pours
• Lead the redesign of legacy pattern plates that cause mold shift and poor yield, including planning and managing the changeover to new tooling
• Create 3D models, drawings, and CNC-ready models, and work with CNC programmers and the Tool Room so tooling is machined accurately and efficiently
• Apply pattern allowances (shrinkage, draft, machining stock), parting line placement, and GD&T to all tooling designs
• Lead first-article and trial runs for new or modified tooling; analyze casting defects and make design corrections
• Track scrap, yield, and mold shift results before and after tooling changes, and report on improvements
• Maintain tooling records, revision control, and pattern and plate documentation
• Provide design-for-casting input to NPD and Product Engineering on new parts
• Collaborate with team members to increase overall throughput
• Complete all necessary documents fully and accurately
• Adhere to 5S standards (e.g., maintain cleanliness of work area, etc.)
• Follow all Safety, Environmental and Quality policies and procedures
• Perform other duties as assigned

Experience and Education

• Bachelor's degree in Mechanical, Manufacturing, or Metallurgical Engineering, or equivalent experience
• 3+ years of experience in tooling or pattern design for a sand casting foundry
• Hands-on experience with MAGMA (MAGMASOFT) or similar casting simulation software
• Proficiency in 3D CAD software (SolidWorks or similar) and creating production drawings
• Working knowledge of CNC machining and design for manufacturability
• Perform work under minimal supervision and refer only the most complex issues to higher level staff

Competencies/ Skills

• Ability to set up, run, and interpret MAGMA casting simulations
• Strong knowledge of the sand casting process, including molding, coring, gating, risering, and shrinkage
• 3D modeling, detailed drawing, and GD&T skills
• Strong problem-solving skills, including root cause analysis tools (5 Why, fishbone, 8D)
• Ability to analyze scrap and yield data, manage multiple tooling projects, and meet deadlines
• Strong verbal, written, and interpersonal communication skills