Casting Process Simulation & Yield Improvement Intern
About The Position
Wisconsin Aluminum Foundry is hiring a paid intern for a 12–14-week summer engineering project in Manitowoc, Wisconsin, running from May or June through August 2027. The intern will use MAGMA and SolidWorks on production castings to identify losses in metal, time, and cost, then test and demonstrate improvements on the foundry floor. The role involves working alongside engineers and operators and presenting measurable results and recommendations to WAF leadership at the end of the summer. The project focuses on improving casting yield and reducing scrap and finishing effort. The intern will model solidification, filling, and gating; redesign gating, risers, and feeding; test changes with process engineers and foundry staff; and compare production data before and after changes. Expected project outcomes include reporting scrap dollars saved, annual aluminum pounds saved and their dollar value, and finishing time reduced per part where applicable.
Requirements
- Be pursuing a degree in mechanical, materials, metallurgical, or manufacturing engineering.
- Understand solidification and gating principles.
- Have experience with SolidWorks or similar 3D CAD software.
- Have problem-solving ability, including investigating root causes rather than only symptoms.
- Demonstrate attention to detail with data and measurements.
Nice To Haves
- Experience with MAGMA, Flow-3D, or other casting simulation software.
- Coursework in foundry processes.
Responsibilities
- Model solidification, filling, and gating for target production jobs in MAGMA.
- Redesign gating, risers, and feeding in SolidWorks to improve yield and reduce scrap.
- Test design changes on the foundry floor with process engineers and foundry staff.
- Track scrap, pour weight, and finishing time before and after each change.
- Identify opportunities to reduce grinding, cut-off, and other finishing time.
- Present results and recommendations to WAF leadership in August.
- Report scrap dollars saved, annual pounds of aluminum saved and their dollar value, and finishing time reduced per part where applicable.
Benefits
- Paid, hands-on engineering work on parts shipped to real customers.
- Experience with industry-standard simulation software.
- A results story with measurable outcomes for future interviews.
- Mentorship from WAF engineers.
Stand Out From the Crowd
Upload your resume and get instant feedback on how well it matches this job.
What This Job Offers
Career Level
Intern
Education Level
No Education Listed
