Castings Engineer

Linamar Corporation•Livonia, MI

About The Position

The Casting Engineer is an experienced engineer who is the primary person responsible for developing casting solutions for parts created by product engineering or received from a customer technical liaison. The role identifies an optimal casting process and layout, then develops casting solutions and tooling that meet customer requirements. The engineer works at a fast pace with minimal supervision in a technical environment where business needs may bring frequent interruptions and changing priorities. The position covers casting process modeling and tooling design, manufacturing support, technical liaison work, program support, continuous improvement, and career development. It includes developing and validating casting concepts, supporting prototype and production programs, coordinating tooling suppliers, helping manufacturing resolve process and quality issues, and contributing to launches and cost or scrap reduction initiatives. The engineer also provides technical guidance and knowledge sharing to engineering and manufacturing personnel.

Requirements

Experience developing casting designs, gating and riser systems, cooling strategies, and mold layouts.
Experience with casting simulation software such as MAGMASOFT, FLOW-3D, EKK, or equivalent.
Proficiency with Siemens NX or equivalent 3D CAD software for casting and tooling design.
Knowledge of aluminum, magnesium, and iron alloys, material specifications, and casting process capabilities.
Working knowledge of APQP, PPAP, engineering change control, basic statistics, DOE, and CAE analysis.
Ability to independently prioritize work, solve technical problems, communicate with customers and suppliers, and support multiple programs in a fast-paced environment.

Nice To Haves

Bachelor’s degree in mechanical engineering, Manufacturing Engineering, Materials Engineering, or a related technical discipline is preferred.
Casting process engineering experience and casting tooling design experience are preferred.

Responsibilities

Evaluate casting designs for manufacturability and develop robust casting solutions that meet customer, quality, cost, and production requirements.
Develop casting concepts, gating systems, runners, risers, cooling circuits, venting systems, and mold layouts for prototype and production applications.
Perform and interpret casting simulations to optimize metal flow, solidification, thermal management, and casting quality.
Apply metallurgy, statistical analysis, Design of Experiments, CAE validation, and process capability analysis to product and process development.
Support aluminum, magnesium, and ferrous casting processes, including HPDC, Squeeze Casting, Gravity Casting, Permanent Mold, Semi-Permanent Mold, Sand Casting, Tilt Pour, PCPC, and VRC/PRC technologies.
Design, develop, and support prototype and production tooling using Siemens NX or equivalent CAD platforms.
Coordinate tooling development with internal and external suppliers and provide technical support through design, build, validation, and launch.
Establish and maintain process documentation, setup parameters, tooling standards, engineering records, and revision control.
Support manufacturing plants with tooling and process troubleshooting and maintain current tooling and process revisions.
Support prototype builds, APQP activities, PPAP submissions, process validation, production launches, and manufacturing readiness reviews.
Provide technical support to manufacturing facilities to resolve casting, tooling, process, quality, productivity, and launch-related issues.
Lead or support root-cause investigations, corrective actions, process optimization, and scrap reduction using structured problem-solving methods.
Act as a technical liaison among product engineering, manufacturing facilities, suppliers, tool shops, and customers regarding design, manufacturing, and process requirements.
Participate in internal and customer design reviews and recommend improvements to manufacturability, quality, cost, and operational performance.
Support engineering change management, including evaluation, implementation, validation, and approval of design and process changes.
Support the Program Manager, manufacturing lead meetings, launch-readiness activities, trials, and launches at Linamar and supplier facilities.
Support plant scrap-reduction, tooling-improvement, and troubleshooting projects.
Track annual savings and lead or support value analysis/value engineering activities.
Provide input to management regarding personal development and perform other duties as assigned.
Mentor and support engineering and manufacturing personnel through technical guidance, training, and knowledge sharing.