Castings Engineer (OEM)

SUMMARY:  The Casting Engineer is responsible for the design, manufacture, and control of aluminum and steel castings. The role will involve collaborating with design teams, suppliers, and manufacturing facilities to ensure the production of high-quality castings that meet stringent regulatory standards and OEM specifications.

DUTIES & RESPONSIBILITIES:

Responsibilities include, but are not limited to:

• Work collaboratively with the casting supplier to ensure the casting tooling and process is adequate to control / minimize core shifts, porosity, voids, laps, and other casting defects.
• Collaborate with design engineers to develop casting designs for aerospace components, ensuring adherence to performance requirements, manufacturability, and cost-effectiveness. Utilize CAD/CAM software to create casting models, molds, and tooling designs.
• Work with materials engineering teams to select appropriate casting materials and optimize casting processes (e.g., sand casting, investment casting) for aerospace applications. Conduct material testing and process validation to ensure product integrity and performance.
• Identify and qualify casting suppliers capable of meeting aerospace industry standards and regulatory requirements. Establish and maintain relationships with suppliers, conduct audits, and provide technical support to ensure the quality and reliability of cast components.
• Develop and implement quality control measures and inspection procedures for castings, ensuring compliance with OEM specifications, industry standards, and regulatory requirements (e.g., NDT testing, dimensional inspection). Perform root cause analysis and implement corrective actions to address quality issues and non-conformities.
• Identify opportunities for process optimization, cycle time reduction, and waste elimination in casting manufacturing processes. Implement changes to streamline production workflows, enhance productivity, and reduce manufacturing costs.
• Generate and maintain casting documentation, including manufacturing specifications, work instructions, and quality records. Ensure accuracy, completeness, and compliance with regulatory standards and OEM requirements.
• Participate in new product introduction (NPI) projects, providing casting engineering input to design reviews, prototype builds, and validation testing activities. Ensure smooth transition of new cast components from development to production, addressing any manufacturing challenges or constraints.
• Stay abreast of industry trends, technological advancements, and best practices in casting engineering. Identify areas for continuous improvement in casting design, materials, and processes to enhance product performance, reliability, and efficiency.
• Other duties as assigned.

MINIMUM REQUIREMENTS: 

• Bachelor’s degree in materials engineering, mechanical engineering, metallurgical engineering, or related field.
• 5 years of casting engineering experience in the aviation industry, preferably with an OEM or aerospace manufacturer.
  • OR an additional 3 years of engineering experience in lieu of degree.
• Must be knowledgeable on the casting processes for sand castings, die castings, investment castings, and permanent / semi-permanent mold castings.
• Knowledge of casting heat treatment process, hot isostatic press process, and weld repair process.
• Proficient in solid modelling using CAD software.
• Knowledge and understanding of x-ray, CT scan, and other non-destructive techniques for casting inspections. Comparison of CT scan image with CAD solid model.
• Knowledge of regulatory requirements and certification processes governing aerospace casting manufacturing (e.g., NADCAP, AMS specifications).
• Familiarity with quality management systems and inspection techniques for cast components (e.g., NDT testing, dimensional metrology).
• Excellent problem-solving skills, with the ability to analyze complex casting issues and implement effective solutions.
• Strong communication and interpersonal skills, with the ability to collaborate effectively with cross-functional teams, suppliers, and external stakeholders.

PREFERRED REQUIREMENTS:

• 9+ years of casting engineering experience within the aviation industry.
• Experience with advanced casting technologies such as additive manufacturing (3D printing), rapid prototyping, and computer-aided casting simulation.
• Knowledge of aerospace industry standards and specifications for casting materials, processes, and product certification (e.g., ASTM, SAE).
• Previous experience with supplier qualification and management in aerospace casting supply chains.
• Certification in Lean Six Sigma or other relevant quality management methodologies.

OTHER: 

• The selected applicant will be subject to a background check and drug testing.