Process Engineer

Dicastal North America Inc. • Livonia, MI

117d

About The Position

We are seeking a Casting & Manufacturing Process Engineer with strong expertise in aluminum casting simulation and process development, complemented by knowledge of machining and assembly processes. The primary focus of this role is casting simulation, trial validation, and process optimization, while also supporting downstream machining and assembly operations to ensure seamless product industrialization and drive excellence in manufacturability, quality, and efficiency. The ideal candidate will have deep expertise in hands-on knowledge of Low-Pressure Casting and Counter Pressure Casting technologies.

Requirements

• Bachelor’s or Master’s degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, or related field.
• 5–10 years of experience in process engineering (preferably automotive).
• Strong Proficiency in MAGMA, ProCAST, or other casting simulation software.
• Working knowledge of Lean Manufacturing principles.
• Knowledge of machining fundamentals and assembly requirements.
• Experience writing procedures and work instructions.
• Well-versed in automotive manufacturing standards, quality systems, and core tools such as APQP and PPAP.
• Working knowledge of word processing and spreadsheet software in use.
• Proven track record in supporting global, cross-cultural engineering projects and diverse team environments.
• Strong written and verbal communication skills in English, with all levels of the company.
• Mandarin Chinese proficiency (written/verbal) is a plus.

Responsibilities

• Perform advanced casting simulations using MAGMA, ProCAST or other software.
• Analyze simulation outputs for mold filling, temperature gradients, solidification behavior, and potential defect formation.
• Lead casting trials to validate simulation results and refine key process parameters for optimal outcomes.
• Direct mold design efforts and establish robust casting process settings to ensure repeatability and quality.
• Develop and implement process standards, best practices, and defect prevention guidelines specific to aluminum casting operations.
• Evaluate machining sequences, fixturing solutions, and dimensional tolerances to ensure compatibility with casting design and processes.
• Collaborate closely with cross-functional manufacturing teams to troubleshoot and resolve quality issues across casting, machining, and assembly stages.
• Prepare detailed technical documentation, including reports and presentations, utilizing Microsoft Word and PowerPoint.
• Communicate findings, insights, and technical recommendations to engineering, tooling, machining, and manufacturing teams.
• Drive continuous improvement initiatives aimed at enhancing yield, reducing defects, and improving cost efficiency.
• Occasional business travel to China and Mexico.

What This Job Offers

• Education Level: Bachelor's degree
• Number of Employees: 251-500 employees