Tool Design Engineer

Job Summary

Designs and develops foundry tooling for a sand casting operation, with a focus on patterns, pattern plates, and core boxes. This role uses MAGMA casting simulation to model mold filling and solidification, and designs new plates to replace legacy tooling that contributes to mold shift and poor yield. The engineer works with the Foundry, South Floor, Tool Room, and CNC teams to improve casting quality, yield, and throughput.

Job Duties

• Design and develop foundry tooling for sand casting, including patterns, match plates, cope and drag plates, core boxes, and related fixtures
• Run MAGMA casting process simulations of mold filling, solidification, and cooling to predict and prevent defects such as shrinkage, porosity, misruns, and cold shuts
• Design and optimize gating, runner, riser, and feeding systems, and validate them through simulation and trial pours
• Lead the redesign of legacy pattern plates that cause mold shift and poor yield, including planning and managing the changeover to new tooling
• Create 3D models, drawings, and CNC-ready models, and work with CNC programmers and the Tool Room so tooling is machined accurately and efficiently
• Apply pattern allowances (shrinkage, draft, machining stock), parting line placement, and GD&T to all tooling designs
• Lead first-article and trial runs for new or modified tooling; analyze casting defects and make design corrections
• Track scrap, yield, and mold shift results before and after tooling changes, and report on improvements
• Maintain tooling records, revision control, and pattern and plate documentation
• Provide design-for-casting input to NPD and Product Engineering on new parts
• Collaborate with team members to increase overall throughput
• Complete all necessary documents fully and accurately
• Adhere to 5S standards (e.g., maintain cleanliness of work area, etc.)
• Follow all Safety, Environmental and Quality policies and procedures
• Perform other duties as assigned

Experience and Education

• Bachelor's degree in Mechanical, Manufacturing, or Metallurgical Engineering, or equivalent experience
• 3+ years of experience in tooling or pattern design for a sand casting foundry
• Hands-on experience with MAGMA (MAGMASOFT) or similar casting simulation software
• Proficiency in 3D CAD software (SolidWorks or similar) and creating production drawings
• Working knowledge of CNC machining and design for manufacturability
• Perform work under minimal supervision and refer only the most complex issues to higher level staff

Competencies/ Skills

• Ability to set up, run, and interpret MAGMA casting simulations
• Strong knowledge of the sand casting process, including molding, coring, gating, risering, and shrinkage
• 3D modeling, detailed drawing, and GD&T skills
• Strong problem-solving skills, including root cause analysis tools (5 Why, fishbone, 8D)
• Ability to analyze scrap and yield data, manage multiple tooling projects, and meet deadlines
• Strong verbal, written, and interpersonal communication skills