Process Engineer, High Pressure Die Casting

Rocket City HR•Grafton, WI

2d•Onsite

About The Position

The Process Engineer - HPDC is responsible for developing, optimizing, and maintaining die casting processes to ensure high-quality production, cost efficiency, and operational reliability. This role will lead continuous improvement initiatives, support new product launches, and provide technical expertise in die casting, melting, trimming, and finishing processes.

Requirements

Bachelor's degree in Mechanical, Industrial, Metallurgical, or Manufacturing Engineering (or related field).
3-5 years of experience in high-pressure die casting (HPDC) process engineering.
Hands-on experience with die casting machines (Bühler, Idra, Toshiba, etc.) and auxiliary equipment.
Strong background in metallurgy, solidification, and casting defects.
Familiarity with CAD software (SolidWorks, AutoCAD, CATIA, etc.) and simulation tools (MAGMASoft, ProCAST).
Strong analytical and problem-solving skills.
Knowledge of Lean Manufacturing, Six Sigma, and statistical process control (SPC).
Ability to manage multiple projects and work cross-functionally.
Excellent communication skills (written and verbal).
Proficiency in MS Office (Excel, Word, PowerPoint).
Technical expertise in die casting processes.
Results-oriented with a continuous improvement mindset.
Team player with leadership potential.
Ability to work in a fast-paced manufacturing environment.

Nice To Haves

Master's degree preferred but not required

Responsibilities

Design, develop, and optimize HPDC processes, including machine parameters, gating design, and cooling systems.
Analyze process capability and implement improvements to increase yield, reduce scrap, and enhance cycle times.
Support tooling design and modifications for die casting molds.
Troubleshoot die casting equipment, tooling, and process issues in real time to minimize downtime.
Develop and maintain standard operating procedures (SOPs) and process documentation.
Ensure compliance with quality standards (IATF 16949, ISO 9001, etc.).
Conduct root cause analysis for quality defects (porosity, cold shuts, flash, etc.) and implement corrective actions.
Lead continuous improvement initiatives using Lean Manufacturing, Six Sigma, and Kaizen methodologies.
Collaborate with Quality and Maintenance teams to ensure consistent part quality.
Support APQP, PPAP, and new product introduction (NPI) processes for HPDC components.
Participate in trial runs, parameter development, and validation of new tools.
Work closely with design engineering to ensure manufacturability.
Promote and enforce EHS standards in die casting operations.
Ensure compliance with all company, customer, and regulatory requirements.