Casting Engineer

Charter Manufacturing is a fourth-generation family-owned business where our will to grow drives us to do it better.  Join the team and become part of our family!

Charter Casting is hiring a Casting Engineer!

Alternative Job Titles: Foundry Engineer, Casting Development Engineer, Iron Casting Engineer, Foundry Process Engineer

About Charter Casting:

Charter Casting is a U.S.-based manufacturer of large complex iron castings and DuraBar®, the industry’s leading continuous cast iron bar. Our operations combine advanced molding capacity, disciplined process control, and hands-on engineering collaboration to deliver consistent quality at an industrial scale. Charter Casting is a member of the Charter Manufacturing family of companies.  

Job Summary:  

Serve as a technical resource for green sand foundry operations, providing expertise in gating and riser design, pattern and core box construction, parting line strategy, dimensional control, and grey and ductile iron processing. Support customer technical discussions to ensure castings meet material and dimensional requirements, while driving process optimization, continuous improvement, and production stability. Contribute to engineering standards and support effective PPAP execution for new and existing programs.

Position specifics:

• Location: Shawano WI

• Schedule: Onsite

• Travel: Up to 15% domestic travel for customer visits and supplier/manufacturing partners.

• Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor for employment visas at this time.

Key responsibilities:

• Design and optimize gating and riser systems to support directional solidification and improved yield

• Review and provide input on pattern equipment, core box design, and tool layout to support manufacturability and dimensional stability

• Recommend parting line and mold orientation strategies to improve feeding and dimensional performance

• Lead technical problem solving related to mold and core interaction impacting quality and performance

• Conduct Root Cause Analysis involving feeding, tooling, mold design, dimensional instability, and iron behavior

• Ensure castings meet blueprint and dimensional requirements through tooling, process, and design adjustments

• Apply technical knowledge of grey and ductile iron behavior to support casting soundness

• Utilize casting simulation and process analysis tools to support feeding optimization, dimensional stability, and manufacturability improvements

• Support process capability improvement through data analysis, process monitoring, and corrective action implementation

• Develop and maintain engineering documentation, process records, and technical standards related to casting processes

• Support Production Part Approval Process (PPAP) activities, including dimensional validation, PFMEA input, Control Plan review, and launch readiness

• Serve as technical liaison between Engineering, Tooling, Quality, Production, and Commercial teams, as required

What you’ll need:

• Bachelor’s Degree in Engineering (Mechanical, Metallurgical, Materials Science, or related field) or equivalent combination of education and experience

• 3+ years of progressive foundry engineering experience in a green sand iron casting environment

• Demonstrated proficiency in gating and riser design

• Working knowledge of pattern equipment and core box construction

• Strong understanding of blueprint reading and dimensional control

• Familiarity with solidification software, MAGMA preferred

Nice to haves:

• Master’s Degree in Engineering (Mechanical, Metallurgical, Materials Science, or related field) or equivalent combination of education and experience

• 5+ years of progressive foundry engineering experience in a green sand iron casting environment

• Experience in grey and ductile iron casting

• Experience using casting simulation software

• Experience supporting PPAP submissions and customer technical reviews

Take the next step in your career, apply today!

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We offer comprehensive health, dental, and vision benefits, along with a 401(k) plan that includes employer matching and profit sharing. Additionally, we offer company-paid life insurance, disability coverage, and paid time off (PTO).