Senior Foundry Engineer

Fabri•Boston, MA

4d•Onsite

About The Position

Fabri is seeking a Senior Foundry Engineer to build and own the process development of high-performance superalloy castings for demanding aerospace and space-industry applications. This role is for someone who has operated inside a high-tempo, high-accountability foundry environment and wants direct ownership over how critical hardware is melted, cast, solidified, inspected, and iterated on, using first-principles physics rather than legacy playbooks. You will drive the development of Fabri’s high-temperature casting capability, starting with equiaxed superalloy castings and expanding toward more advanced solidification approaches over time. The emphasis is on process execution, defect elimination, and repeatable quality suitable for flight-critical hardware. We are an early-stage investment casting startup building a fully integrated digital foundry. Our mission is to deliver precision metal castings with unparalleled speed and cost-effectiveness. By leveraging our exclusive high-throughput additive manufacturing process and AI-driven design software, we can deliver castings in days, saving our customers critical time and money. We are well capitalized and backed by top-tier investors and major customers, with significant funding raised in the past year. We’ve shipped our first customer parts and have generated significant commercial excitement in both the aerospace and industrial sectors. Fabri is located in Boston Metrowest. During this startup phase and for the foreseeable future, all employees will be on-site and closely involved with building and operating the end-to-end process. Fabri is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. We foster an environment where safety and commitment to quality are central in everything we do.

Requirements

Bachelor’s, Master’s, or PhD in Materials Science, Metallurgical Engineering, Mechanical Engineering, Aerospace Engineering, or a closely related field.
5+ years of experience running foundry casting processes for aerospace, space, or other high-consequence hardware.
Strong first-principles understanding of casting-relevant physics, including heat transfer, fluid flow, solidification, phase transformations, grain structure control, and surface phenomena.
Understanding of Statistical Process Control (SPC) and Design of Experiments (DOE) methods in improving and maintaining high quality casting processes
Demonstrated experience identifying casting defects, performing root-cause analysis, and driving process changes to eliminate them.
Hands-on experience working directly on the foundry floor, operating equipment and executing process steps alongside technicians and engineers.
Ability to operate effectively in a startup environment with high ownership, ambiguity, and a bias toward execution.
Ability to rapidly identify, learn, and reason across diverse, multi-disciplinary physics domains and process steps using a systems-engineering mindset, applying strong theoretical fundamentals to solve complex problems efficiently.
To comply with ITAR regulations, candidates for this role must be US nationals (i.e., US citizens or lawful permanent residents) to be considered.

Nice To Haves

Direct experience with superalloy investment casting for aerospace or space applications.
Exposure to directionally solidified and/or single-crystal casting processes.
Experience spanning multiple foundry functions, including patterns, shelling, casting, and post-processing.
Experience using thermal, fluid, or solidification simulation tools to inform process decisions.
Experience working in an AS9100-compliant environment.
Prior work in a startup or rapid-iteration manufacturing environment.
Experience in a startup with high ownership and ambiguity.

Responsibilities

Own process development and production readiness for aerospace superalloy castings (e.g., Ni-, Co-, and Ti-base systems), with a focus on repeatability, yield, and defect reduction.
Develop and mature equiaxed casting processes as the initial foundation of Fabri’s high-temperature capability, while applying experience from directionally solidified (DS) and/or single-crystal (SCX) systems to produce the highest quality castings, and enable future process expansion.
Design and control solidification behavior to manage grain structure, segregation, phase evolution, shrinkage, hot tearing, porosity, surface condition, and dimensional stability using a combination of SPC, DOE methods, and physics-based reasoning.
Work closely with the software team to develop thermal and solidification simulations to guide gating, risering, mold design, and thermal control decisions.
Work across the full foundry stack as needed, including patterns, shell systems, melt practice, pouring, and post-cast processing, ensuring strong linkage between process inputs and measured outcomes.
Partner with equipment, mechanical design, and automation engineers to define requirements and build custom foundry hardware that enables new casting and solidification approaches.
Interface directly with customers and internal stakeholders on technically deep discussions around material selection, casting strategy, qualification approach, and production readiness.
Rapidly transition processes from development into stable production ownership, moving programs forward at a pace consistent with modern aerospace and spaceflight development.