Tooling Design Engineer - Sand Casting & MAGMA Simulation

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

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