Casting Engineer

Charter Manufacturing•Shawano, WI

3d•Onsite

About The Position

Charter Manufacturing is a fourth-generation family-owned business seeking a Casting Engineer. 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. This role serves 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. The Casting Engineer will support customer technical discussions to ensure castings meet material and dimensional requirements, while driving process optimization, continuous improvement, and production stability. This position also contributes to engineering standards and supports effective PPAP execution for new and existing programs.

Requirements

Bachelor’s Degree in Engineering (Mechanical, Metallurgical, Materials Science, or related field) or equivalent combination of education and experience
8+ years of progressive foundry engineering experience in a green sand iron casting environment
Advanced expertise in gating and risering design
Strong knowledge of pattern equipment and core box construction
Strong understanding of blueprint reading and dimensional control
Familiarity with solidification software (MAGMA)
Applicants must be authorized to work for any employer in the U.S.

Nice To Haves

Master’s Degree in Engineering (Mechanical, Metallurgical, Materials Science, or related field) or equivalent combination of education and experience
10+ years of progressive foundry engineering experience in a green sand iron casting environment
Extensive experience in grey and ductile iron casting, including in-mold processing
Advanced casting simulation proficiency
Experience leading complex PPAP submissions and customer technical reviews

Responsibilities

Establish and lead advanced gating and risering strategies to ensure directional solidification and optimized yield
Evaluate and influence pattern equipment, core box design, and tool layout for manufacturability and dimensional stability
Define parting line and mold orientation strategies to support feeding, structural integrity, and dimensional control
Provide technical leadership in mold and core interaction issues impacting quality and performance
Investigate 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
Provide advanced technical knowledge of in-mold grey and ductile iron behavior to support casting soundness
Utilize advanced casting simulation and process analysis tools to optimize tooling design, feeding strategy, dimensional stability, and manufacturability
Lead process capability improvement initiatives through advanced data analysis, process monitoring, and corrective action implementation
Establish, maintain, and improve engineering documentation, process records, technical standards, and best practices related to casting processes
Lead and support Production Part Approval Process (PPAP) activities, including dimensional validation, PFMEA input, Control Plan review, and launch readiness
Serve as senior technical liaison between Engineering, Tooling, Quality, Production, and Commercial teams
Mentor and support the technical development of engineers, tooling personnel, and operations teams