Overview

The NPI Casting Process Engineer drives casting optimization and process development during the early stages of new product integration; translating complex design intent into manufacturable, high-quality casting solutions. This role works cross-functionally with CAD Developers, Project Leads, and Manufacturing Engineers to ideate and refine sprue systems, leveraging an in-depth understanding of fluid dynamics, solidification behavior, shrinkage compensation, and defect mitigation strategies. Utilizing advanced flow simulation tools, the engineer analyzes fill and solidification results to predict and resolve potential issues including porosity, cracking, cold shuts, and incomplete fills. These insights guide iterative sprue optimization and process parameter adjustments. The engineer is responsible for initiating and managing trial casting work orders, evaluating physical samples for quality, dimensional accuracy, and surface finish, and using non-destructive testin...