Design Engineer 4 Foundry Tooling / CAD

Shift: 1st Shift: 6:00 AM 2:30 PM

1 round
Virtual/Phone and In-Person options
Panel interview
Interviews generally available Tuesday Thursday around 3:00 PM

Client is looking for an experienced Design Engineer with strong foundry engineering, foundry tooling design, CAD modeling, and casting simulation experience.

The engineer will be responsible for designing and developing foundry tooling using Creo, following established standards and best practices for No-Bake molding processes. The primary objective is to improve casting quality, reduce scrap and defects, and reduce lead time associated with tooling construction.

This is a hands-on role that requires strong knowledge of foundry processes, casting, tooling, pattern/core box design, CAD modeling, machining drawings, and casting simulation.

Design foundry tooling using Creo and established design standards/best practices.
Design new pattern tooling and core boxes for foundry applications.
Support tooling RFQs, quotations, and tooling build projects.
Analyze casting scrap, defects, and manufacturing issues and develop solutions.
Resolve casting issues through tooling/design modifications.
Perform re-gating and tooling modifications as required.
Conduct and interpret casting flow/fill simulation, preferably using SolidCast.
Develop complex CAD models while considering parting lines, offsets, clearances, and tooling build requirements.
Review and interpret machining prints, drawings, and geometric tolerances.
Work closely with pattern makers, pattern technicians, manufacturing engineers, programmers, and other tooling designers.
Provide tooling build direction and technical guidance to pattern makers and suppliers.
Work with external suppliers on tooling build projects and ensure designs meet requirements.
Support continuous improvement initiatives focused on quality improvement, scrap reduction, and tooling lead-time reduction.
Troubleshoot tooling and casting problems and implement practical engineering solutions.
Communicate project status, priorities, and technical issues with management and cross-functional teams.

5+ years of relevant professional experience in foundry engineering, foundry tooling, or a closely related field.
Associate or Bachelor's degree in Engineering, Manufacturing, Mechanical Engineering, or a related technical discipline.
Strong foundry engineering experience.
Strong foundry tooling design experience using CAD.
Hands-on experience with Creo or comparable CAD software.
Experience with casting simulation, preferably SolidCast.
Strong understanding of No-Bake molding processes.
Knowledge of Cold Box processes.
Experience with pattern and core box design.
Strong understanding of parting lines (P/L), offsets, clearances, and tooling layouts.
Ability to read and interpret machining prints and geometric tolerances/GD&T.
Strong problem-solving and troubleshooting skills.
Ability to communicate effectively with engineers, managers, pattern makers, suppliers, and shop-floor personnel.
Important Experience Requirement

Internships do NOT count toward the required professional experience.

1. Foundry Engineering Experience

Candidates should have hands-on experience with:

Foundry processes
Tooling quotations/RFQs
Casting scrap and defect analysis
Casting defect resolution
No-Bake molding
Cold Box processes

2. Foundry Tooling Design + CAD

Strong experience with:

Pattern design
Core box design
Complex CAD modeling
Parting lines
Offsets
Clearances
Tooling layouts
No-Bake and/or Cold Box tooling
Creo experience is strongly preferred.

3. Creo + Casting Simulation

Strong Creo modeling experience
Casting/flow simulation experience
SolidCast is preferred

Strong CAD/design skills Creo preferred
Machining print reading
Geometric tolerancing / GD&T
Casting simulation experience
Understanding of foundry tooling and casting processes
Preferred / Nice to Have

CNC milling knowledge
Experience working directly with tooling suppliers
Experience with complex casting/tooling projects
Additional foundry process knowledge

Soft Skills

The successful candidate should be able to:

Work independently and manage priorities effectively.
Communicate clearly with all levels of the organization.
Work directly with suppliers on tooling build projects.
Provide technical direction to pattern makers and tooling teams.
Collaborate effectively with managers, engineers, designers, programmers, and shop-floor personnel.
Troubleshoot problems and make practical, timely engineering decisions.

Team Structure

The candidate will work with a cross-functional foundry/tooling team consisting of:

Managers
Foundry Tool Designers
Manufacturing Engineers
Programmers
Pattern Makers
Pattern Technicians
The role requires frequent interaction with managers regarding priorities and workflow, as well as close collaboration with tool designers, engineers, pattern makers, and suppliers.

Typical Day / Responsibilities

Typical work may include:

Reviewing RFQs and tooling requirements
Designing new pattern tooling
Designing/modifying core boxes
Resolving casting defects and production issues
Performing re-gating
Running/reviewing casting simulations
Making CAD/tooling modifications
Supporting tooling builds
Working with pattern makers and suppliers
Reviewing machining drawings and tolerances
Supporting other foundry/tooling engineering activities as needed

Work Environment

This position is based in a foundry production environment and will involve a combination of:

Office/computer-based CAD work
Shop-floor activities
Foundry production areas
Interaction with tooling and manufacturing teams
Important: The foundry environment can be hot during the summer and cold during the winter, so candidates should be comfortable working in a manufacturing/foundry setting.

Candidate Red Flags / Disqualifiers

Do NOT submit candidates who have:

No foundry experience
No foundry tooling experience
No CAD-based tooling design experience
No experience designing patterns/core boxes or similar foundry tooling
No understanding of casting processes
Only internship experience without the required professional experience
Strongly Preferred

Candidates with Creo + SolidCast + foundry tooling design + No-Bake/Cold Box experience should be prioritized.

The ideal candidate is a Foundry Engineer / Foundry Tooling Designer / Manufacturing Engineer with approximately 5+ years of hands-on professional experience designing casting tooling.

A strong candidate will have experience with Creo, pattern/core box design, No-Bake molding, Cold Box processes, casting defect analysis, tooling RFQs, casting simulation/SolidCast, machining drawings, and GD&T.

Candidates coming from foundry tooling design, casting engineering, pattern/tool design, or similar manufacturing environments are the best fit.

Himanshu Goswami

Sr. IT Technical Recruiter

Stellent IT Phone:

Email: Himanshu.goswami
Gtalk: Himanshu.goswamiom