NPI Process Engineer Casting

Tiffany & Co.•Cumberland, RI

2d•Onsite

About The Position

The NPI Casting Process Engineer drives casting optimization and process development during the early stages of new product integration, translating complex design intent into manufacturable, high-quality casting solutions. This role involves cross-functional collaboration with CAD Developers, Project Leads, and Manufacturing Engineers to ideate and refine sprue systems, leveraging an in-depth understanding of fluid dynamics, solidification behavior, shrinkage compensation, and defect mitigation strategies. The engineer utilizes advanced flow simulation tools to analyze fill and solidification results, predicting and resolving potential issues such as porosity, cracking, cold shuts, and incomplete fills. These insights guide iterative sprue optimization and process parameter adjustments. The engineer is responsible for initiating and managing trial casting work orders, evaluating physical samples for quality, dimensional accuracy, and surface finish, and employing non-destructive testing (NDT) methods when appropriate. This role ensures that validated casting designs meet aesthetic and functional requirements prior to production handoff. Final deliverables include detailed casting documentation packages—comprising simulation results, sprue/gating CAD models, validated process parameters, and recommended SOP inputs—that facilitate a seamless transition to manufacturing while supporting first-time quality and long-term process stability.

Requirements

Bachelor’s degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, or a related discipline; or equivalent hands-on experience in casting process development within the jewelry industry.
Strong ability to analyze and solve complex casting process challenges using Root Cause Analysis methods.
Experience managing multiple projects simultaneously in a fast-paced New Product Integration (NPI) environment, with strong organizational and time management skills.
Understanding of metallurgical fundamentals relevant to precious metals.
Ability to perform hands-on inspections of cast parts.
Working knowledge of CAD software, particularly tools like Rhino and/or Solid works.
Excellent communication skills (written, verbal, and presentation) to effectively collaborate with cross-functional teams including CAD, manufacturing, and quality.
Advanced proficiency in Microsoft Office Suite, particularly Excel.
Proficiency in statistical analysis and process control technique.

Nice To Haves

Hands-on experience with simulation software relevant to manufacturing.
Knowledge of modern jewelry manufacturing techniques.
Direct experience in jewelry casting processes, including investment casting.
Familiarity with project management tools such as Wrike.
Knowledge of advanced data tools PDM/PLM, ERP, and Tulip systems.
Experience supporting product launches and production ramp-up.

Responsibilities

Lead casting design validation by thoroughly analyzing casting simulation data and physical trial casting results to identify potential issues.
Utilize advanced casting simulation software to evaluate variables that impact casting quality and reduce scrap rates.
Work closely with CAD and Engineering teams to iterate on casting designs, balancing manufacturability, mechanical properties, and aesthetic requirements to meet both engineering and design expectations.
Manage trial casting activities by coordinating with cross-functional teams to create detailed work orders, schedule test runs, and define acceptance criteria for prototype castings.
Lead the hands-on evaluation of cast parts, performing dimensional inspections, non-destructive testing (NDT), and other analysis to verify accuracy and conformity to specifications.
Capture and analyze process data to diagnose deviations and recommend iterative adjustments to sprue design, tree setup, or casting parameters.
Document findings and communicate results effectively to stakeholders to support timely decision-making and minimize development cycle time.
Apply lean manufacturing and quality tools to identify inefficiencies, bottlenecks, and sources of casting defects early in the NPI process.
Use data-driven approaches to prioritize improvements and implement corrective actions that enhance yield, reduce cycle time, and improve overall process robustness.
Continuously monitor process metrics during ramp-up phases, driving a culture of continuous improvement and ensuring sustainable quality performance.
Drive continuous innovation and technology adoption by researching and evaluating emerging casting technologies, materials, and process improvements.
Identify opportunities to incorporate advanced methods such as additive manufacturing for mold creation, automation in gating system production, or real-time process monitoring sensors.
Collaborate with NPI and manufacturing teams to pilot new techniques, assess feasibility, and implement best practices that enhance casting quality, reduce cycle times, and lower overall production costs.
Promote a forward-thinking mindset that keeps the casting process at the forefront of industry advancements and supports long-term competitive advantage.