Product Engineer

Carley Foundry is a full-service casting facility located in Blaine, MN, with over 60 years of excellence in the foundry industry. Renowned for precision and quality, the company offers advanced casting processes and materials to meet demanding specifications across various industries. Capable of handling both high and low-volume production runs, Carley Foundry also excels in prototyping, creating unique solutions where none exist. From small components to castings exceeding 500 pounds, Carley Foundry delivers versatile and reliable results for its customers.

Carley Foundry is seeking an experienced Product Engineer to lead the development, optimization, and launch of complex aluminum casting products. This role combines technical expertise, process innovation, and cross-functional leadership to deliver high-quality manufacturing solutions across multiple product lines.

Product Development & Launch

• Lead new product introduction (NPI) from design through production.
• Collaborate with customers and internal teams to review drawings, specifications, and requirements.
• Develop and validate casting designs, gating/feeding systems, and tooling requirements.
• Lead trials, sampling, and PPAP activities.

Process & Manufacturing Engineering

• Develop and optimize aluminum casting processes including molding, melting, pouring, heat treating, and finishing.
• Troubleshoot defects using root cause analysis and corrective actions.
• Implement improvements using Lean and Six Sigma principles.
• Monitor process metrics and drive improvements in quality, efficiency, and safety.

Technical Leadership

• Lead the design and optimization of gating and riser systems using tools such as DOE, FMEA, and SPC.
• Partner with pattern shops and tooling vendors to create efficient and cost-effective tooling solutions.
• Serve as a technical advisor to production teams on complex casting challenges.
• Mentor engineers and support knowledge sharing across the team.

Operational & Strategic Impact

• Support engineering initiatives aligned with plant safety, quality, productivity, and cost goals.
• Lead commissioning and validation of new product launches and major process changes.
• Contribute to continuous improvement initiatives and strategic planning.
• Support capital projects and technology upgrades.

Required Qualifications

• Bachelor’s or Master’s degree in Engineering or related field
• 5 years of progressive foundry engineering experience
• Strong experience with dry sand, green sand, permanent mold, or investment casting
• Expertise in process optimization, tooling design, and casting development
• Strong analytical, troubleshooting, and problem-solving skills
• Experience leading cross-functional teams and projects

Preferred Experience

• Aluminum casting process expertise
• Lean Manufacturing / Six Sigma methodologies
• Experience with PPAP, DOE, FMEA, and SPC

Why Join Carley Foundry?

• Work on complex, high-impact casting projects
• Collaborate with experienced engineering and manufacturing teams
• Opportunity to influence process innovation and product quality
• Be part of a company focused on continuous improvement and operational excellence

The anticipated salary for this role is $80,000.00-$115,000.00, actual compensation is dependent on demonstrated skills, education and experience.

Benefits: Competitive Salaries, Comprehensive Medical Plans, Health Savings Account (HSA), Vision, Dental, Short-Term Disability, Company Sponsored Basic Life Insurance, Voluntary Life, Spouse and Child Life, 401K Retirement, Parental Leave, Paid Time Off, Employee Assistance Program, Wellness Program, Company Sponsored Events including Annual Holiday Party & Company Picnic.

Join a safety-first, team-driven environment where your work contributes to high-quality castings used in critical industries. Apply today and build your future with us!