Casting Engineer

The Casting Engineer is responsible for developing, optimizing, and supporting die casting manufacturing processes to ensure safe, efficient, and cost-effective production of high-quality cast components. This role works closely with design engineering, quality, maintenance, and production teams to drive continuous improvement, resolve manufacturing issues, and support new product launches. The ideal candidate possesses strong technical expertise in aluminum die casting processes, tooling design, process control, and manufacturing excellence.

Key Responsibilities

• Develop, implement, and optimize die casting processes to meet quality, productivity, and cost objectives.
• Support new product introduction (NPI) activities, including process development, trial runs, and production launch readiness.
• Collaborate with tooling suppliers and internal teams on die design, modifications, and maintenance strategies.
• Analyze casting defects such as porosity, blisters, soldering, flash, and shrinkage, and implement corrective actions.
• Establish and maintain process parameters and documentation.
• Conduct root cause analysis and lead problem-solving activities using tools such as 8D, Fishbone, 5 Why, and FMEA.
• Monitor and improve Overall Equipment Effectiveness (OEE), scrap rates, cycle times, and process capability.
• Support preventive and predictive maintenance programs for die casting equipment and tooling.
• Assist in evaluating and implementing automation solutions, robotics, and process monitoring technologies.
• Participate in capital equipment selection, installation, commissioning, and validation activities.
• Lead continuous improvement initiatives focused on safety, quality, delivery, and cost.
• Support environmental, health, and safety programs while ensuring compliance with company and regulatory requirements.
• Provide technical guidance and training to production personnel, technicians, and maintenance teams.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Metallurgical Engineering, or related technical field.
• Minimum 2 years of experience in die casting manufacturing engineering.
• Experience with aluminum die casting processes.
• Strong understanding of die casting tooling, gating systems, venting, thermal management, and process optimization.
• Knowledge of casting defect analysis and metallurgical principles.
• Experience with statistical process control (SPC) and process capability analysis.
• Proficiency with CAD software (SolidWorks preferred).
• Strong problem-solving, analytical, and project management skills.
• Excellent communication and cross-functional collaboration abilities.

Preferred Qualifications

• 5+ years of die casting engineering experience in an aerospace manufacturing environment.
• Experience with casting simulation software such as MAGMASOFT, Flow-3D Cast, ProCAST, or equivalent.
• Knowledge of Lean Manufacturing, Six Sigma, and continuous improvement methodologies.
• Experience with robotics, automation, and Industry 4.0 technologies.
• Demonstrated ability and willingness to use AI tools to improve productivity, decision-making, work quality, and to reduce costs. The successful candidate must be able to identify appropriate AI use cases and critically evaluate AI-generated outputs.

Physical Requirements

• Ability to work in a manufacturing environment with exposure to heat, noise, and industrial equipment.
• Ability to stand, walk, and move throughout the facility for extended periods.
• Ability to lift up to 25 pounds occasionally.
• Occasional travel to suppliers or customers as required.

Due to the nature of Rotron's programs and products, applicants must have the legal right to work in the US and additionally must be legally authorized to access export-controlled information and source code.