Charter Casting is hiring a Casting Engineer!

Alternative Job Titles: Foundry Engineer, Casting Development Engineer, Iron Casting Engineer, Foundry Process Engineer

Job Summary:  

Serve as a technical resource for green sand foundry operations, providing expertise in gating and riser design, pattern and core box construction, parting line strategy, dimensional control, and grey and ductile iron processing. Support customer technical discussions to ensure castings meet material and dimensional requirements, while driving process optimization, continuous improvement, and production stability. Contribute to engineering standards and support effective PPAP execution for new and existing programs.

Position specifics:

• Location: Shawano WI

• Schedule: Onsite

• Travel: Up to 15% domestic travel for customer visits and supplier/manufacturing partners.

• Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor for employment visas at this time.

Key responsibilities:

• Establish and lead advanced gating and risering strategies to ensure directional solidification and optimized yield

• Evaluate and influence pattern equipment, core box design, and tool layout for manufacturability and dimensional stability

• Define parting line and mold orientation strategies to support feeding, structural integrity, and dimensional control

• Provide technical leadership in mold and core interaction issues impacting quality and performance

• Investigate root cause analysis involving feeding, tooling, mold design, dimensional instability, and iron behavior

• Ensure castings meet blueprint and dimensional requirements through tooling, process, and design adjustments

• Provide advanced technical knowledge of in-mold grey and ductile iron behavior to support casting soundness

• Utilize advanced casting simulation and process analysis tools to optimize tooling design, feeding strategy, dimensional stability, and manufacturability

• Lead process capability improvement initiatives through advanced data analysis, process monitoring, and corrective action implementation

• Establish, maintain, and improve engineering documentation, process records, technical standards, and best practices related to casting processes

• Lead and support Production Part Approval Process (PPAP) activities, including dimensional validation, PFMEA input, Control Plan review, and launch readiness

• Serve as senior technical liaison between Engineering, Tooling, Quality, Production, and Commercial teams

• Mentor and support the technical development of engineers, tooling personnel, and operations teams

What you’ll need:

• Bachelor’s Degree in Engineering (Mechanical, Metallurgical, Materials Science, or related field) or equivalent combination of education and experience

• 8+ years of progressive foundry engineering experience in a green sand iron casting environment

• Advanced expertise in gating and risering design

• Strong knowledge of pattern equipment and core box construction

• Strong understanding of blueprint reading and dimensional control

• Familiarity with solidification software (MAGMA)

Nice to haves:

• Master’s Degree in Engineering (Mechanical, Metallurgical, Materials Science, or related field) or equivalent combination of education and experience

• 10+ years of progressive foundry engineering experience in a green sand iron casting environment

• Extensive experience in grey and ductile iron casting, including in-mold processing

• Advanced casting simulation proficiency

• Experience leading complex PPAP submissions and customer technical reviews

Take the next step in your career, apply today!

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We offer comprehensive health, dental, and vision benefits, along with a 401(k) plan that includes employer matching and profit sharing. Additionally, we offer company-paid life insurance, disability coverage, and paid time off (PTO).