Permanent Mold Process Engineer

WISCONSIN ALUMINUM FOUNDRY CO INC•Manitowoc, WI

21d•Onsite

About The Position

Wisconsin Aluminum Foundry is hiring a Permanent Mold Process Engineer to develop and own robust, repeatable, error-proof permanent mold processes from new job launch through full production. The role covers static, tilt-pour, and low-pressure permanent mold processes, including work with one of the largest permanent mold machines in the country, as the company undertakes a major permanent mold expansion. The engineer remains accountable for the mold and process until production runs correctly, spending substantial time at the machine and working closely with operators, supervisors, Quality, Engineering, and the in-house toolroom.

Requirements

Bachelor's degree in Engineering (Mechanical, Materials, Metallurgical, Manufacturing) or a related field.
Experience in permanent mold, low-pressure permanent mold, or die casting; aluminum experience is preferred.
Understanding of how mold temperature, coatings, and gating affect solidification and casting quality.
Knowledge of aluminum casting alloys and heat-treatment basics.
Ability to troubleshoot using data, technical analysis, and sound judgment.
Ability to make decisions when solutions are not available in a textbook.
Ability to communicate effectively with engineers, toolmakers, and machine operators.

Nice To Haves

Experience with MAGMASOFT.
Experience with SolidWorks.
Experience with aluminum casting.

Responsibilities

Launch new permanent mold jobs from tooling design review through PPAP and steady production.
Set and balance mold thermal management, including die temperatures, water and air cooling, thermocouple placement, and cycle time.
Design and refine gating, risering, and fill for gravity, tilt-pour, and low-pressure molds.
Use MAGMASOFT to predict fill and solidification before tooling is made, then validate the process on the production floor.
Own die coating practices, mold preheat, and core integration for semi-permanent mold jobs.
Address porosity, shrink, cold shuts, and misruns at their root causes using DOE and structured problem solving.
Partner with the in-house toolroom on new molds, modifications, and mold life.
Work with operators, supervisors, Quality, and Engineering to resolve challenging production jobs.
Spend time at the machine troubleshooting permanent mold process problems.
Own the mold and process through successful production operation.