Die Cast Process Engineer
Top Die Casting Company
- South Beloit, IL
- Permanent
- Full-time
- Develop, document, and optimize aluminum die casting processes to ensure repeatability, efficiency, and product quality.
- Establish and monitor key process parameters (e.g., metal temperature, shot speed, intensification pressure, lubrication, cooling time, die temperature, etc.).
- Conduct thorough root-cause analysis for process-related defects such as porosity, short shots, flash, cold shuts, blisters, soldering, and dimensional inconsistencies.
- Implement and maintain robust process control strategies (including SPC) to monitor variation and drive continuous improvement.
- Collaborate with Quality and Production teams to validate first article parts and ensure PPAP submissions meet customer requirements.
- Fully diagnose and repair issues related to die casting machinery, including hydraulic, electrical, pneumatic, and mechanical systems.
- Troubleshoot and correct problems with injection systems, shot ends, hydraulic circuits, temperature control units (TCUs), trim presses, spray systems, and robots.
- Interface with maintenance teams to develop preventive maintenance strategies and machine reliability improvements.
- Support die changeovers and ensure machines return to full operational status with proper setup and verification.
- Analyze die performance and provide input on die design to improve casting quality and cycle time.
- Work with tooling engineers and Tool Shop to recommend improvements for tooling life, cooling channel effectiveness, ejection performance, etc.
- Conduct thermal mapping and thermal balance assessments of dies.
- Develop and maintain detailed process sheets, work instructions, setup documentation, and machine parameter logs.
- Train operators, technicians, and maintenance personnel on correct process parameters, machine operation, and troubleshooting techniques.
- Support the implementation of Industry 4.0 solutions, including sensors, machine monitoring, and data analytics for process control.
- Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Metallurgy, or a related technical field preferred.
- 3–5+ years of experience in aluminum die casting, preferably in a high-volume production environment.
- In-depth knowledge of high-pressure die casting (HPDC) equipment, processes, and materials.
- Strong understanding of die casting machine platforms (e.g., Bühler, Die Cast Press, etc.).
- Ability to read hydraulic/electrical schematics and operate diagnostic tools.
- Familiar with casting simulation software (e.g., Nova-Cast) and process control tools (SPC, DOE, and PFMEA).
- Proficiency with PLC interfaces and industrial automation is a plus.
- Solid knowledge of metallurgy and solidification principles relevant to aluminum alloys.
- Excellent problem-solving and analytical thinking.
- Strong communication skills, both verbal and written.
- Collaborative, hands-on, and results-driven mindset.
- Capable of working independently under pressure with attention to detail.
- Manufacturing plant environment with exposure to heat, noise, and aluminum foundry conditions.
- Must be able to occasionally lift parts and equipment (up to 50 lbs.).
- Must be willing to be on the production floor daily and respond to off-shift emergencies or downtime when needed.
- Six Sigma Green Belt or higher
- Die Casting Society or NADCA technical certification
- OSHA or industrial safety training
- Competitive salary based on experience
- Health, Dental, Vision, and Life Insurance
- 401(k)
- Paid time off and holidays
- Continuing education and training support