Permanent Mold Process Engineer

WISCONSIN ALUMINUM FOUNDRY MASTER • Manitowoc, WI

21d • Onsite

About The Position

Wisconsin Aluminum Foundry is hiring a Permanent Mold Process Engineer to develop 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, including work on a large permanent mold machine as the company expands its permanent mold capacity. The engineer owns processes through successful production and works directly at the machines to resolve issues.

The position involves launching jobs from tooling design review through PPAP and steady production; managing mold thermal conditions; designing and refining gating, risering, and filling; using MAGMASOFT to predict and validate fill and solidification; and managing die coatings, mold preheat, and core integration for semi-permanent mold jobs. The engineer also addresses casting defects through DOE and structured problem solving, collaborates with the in-house toolroom on molds and modifications, and works with operators, supervisors, Quality, and Engineering.

Wisconsin Aluminum Foundry has more than 115 years of experience with aluminum and copper-based casting challenges and is investing in permanent mold capacity, equipment, and its in-house toolroom. The company supports work spanning engineering and prototyping through precision production.

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 answers are not available in a textbook.
• Effective communication with engineers, toolmakers, and machine operators.

Nice To Haves

• Experience with MAGMASOFT.
• Experience with SolidWorks.
• Die casting engineering experience, particularly for candidates moving into permanent mold.

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 practice, 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 on troublesome jobs.
• Spend time at the machine to diagnose and solve permanent mold process problems.

What This Job Offers

• Job Type: Full-time