Tooling Design Engineer - Cast Iron Foundry

Caterpillar Inc.•Hodges, SC

5d•$89,210 - $133,810•Onsite

About The Position

Caterpillar’s Large Power Systems Division designs and manufactures large diesel and natural gas engines, engine components, and powertrains. The Tooling Design Engineer – Cast Iron Foundry will be based in Hodges, South Carolina, and will design, develop, build, implement, and validate foundry tooling used to manufacture cast-iron components. The role applies foundry tooling and casting principles to develop tooling concepts and detailed 3D designs, including patterns, cores, core boxes, core prints, gating systems, filters, risers, and parting lines. The engineer works with design engineering, the tooling shop, quality, suppliers, and manufacturing teams throughout tooling construction, implementation, and validation. The work requires 3D modeling capability and practical knowledge of how foundry tooling is designed, constructed, and used in production. The position is onsite five days per week. Domestic relocation is available; visa sponsorship is not available. The salary range is $89,210 to $133,810. Offers are conditioned on successfully completing a drug screen.

Requirements

Working knowledge of foundry tooling-design and construction principles, including evaluating castings and developing appropriate patterns, cores, core boxes, core prints, parting lines, gating systems, filters, risers, and other tooling features.
Working knowledge of 3D CAD and engineering tools, with the ability to independently develop, analyze, and evaluate 3D foundry-tooling models and detailed tooling designs.
Experience with Creo or comparable 3D parametric CAD/modeling software.
Working knowledge of casting and foundry manufacturing processes, including molding, core-making, tooling construction, metal flow, manufacturability, and casting quality.
Working knowledge of analytical techniques and tools; ability to identify root causes of technical and manufacturing problems and develop effective solutions.
Working knowledge of engineering technologies and their applications, and ability to develop practical solutions to significant technical challenges.
Ability to manage multiple concurrent objectives, projects, or activities and make effective decisions about priorities and time allocation.
Working knowledge of manufacturing product-design processes, approaches, tools, and techniques; ability to translate product and manufacturing requirements into effective tooling designs.
Working knowledge of processes and tools used to design, build, validate, and develop a product or tooling solution from concept through production.

Nice To Haves

Degree from an accredited Engineering or Materials Science curriculum is desired.
Experience with cast-iron foundry tooling design and construction.
Experience developing 3D tooling models for sand-casting applications.
Experience determining cores and core prints for complex castings.
Experience establishing appropriate mold or tooling parting lines.
Experience designing gating systems, risers, filters, and other metal-flow features using established foundry principles.
Experience designing patterns and core boxes.
Experience with gray iron, ductile iron, or comparable sand-casting applications.
Knowledge of no-bake and/or cold-box processes.
Experience with horizontal and/or vertical molding processes.
Experience identifying, troubleshooting, and resolving foundry defects.
Strong working knowledge of foundry manufacturing processes and tooling construction.
Experience with casting simulation software such as MAGMASoft, SolidCast, or comparable software.
Experience supporting tooling from initial design and construction through implementation, validation, and production.

Responsibilities

Design and develop 3D models and detailed designs for cast-iron foundry tooling.
Evaluate casting geometry and determine the cores, core prints, parting lines, gating, risers, filters, and other tooling features required to manufacture castings.
Design and support patterns, core boxes, gating systems, and related foundry tooling using established principles.
Apply practical tooling-construction knowledge to ensure designs can be built, implemented, and used in production.
Develop tooling and gating concepts that support metal flow, casting quality, manufacturability, and production requirements.
Partner with design engineering and the tooling shop throughout tooling construction, implementation, and validation.
Analyze tooling and casting performance and identify solutions to foundry defects, quality concerns, and manufacturing issues.
Research materials, manufacturing methods, tooling concepts, and technologies.
Organize, coordinate, and execute prototype and tooling building, testing, analysis, and validation.
Develop and document functional requirements and translate them into detailed engineering designs.
Participate in design reviews and buy-build analysis for tooling and product components.
Collaborate with supply management and suppliers to support tooling development, quality, and supplier performance.
Participate in proposal preparation, cost estimates, technical documentation, and engineering reports.