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