Senior Foundry Tooling Design Engineer (Creo & Casting Simulation)

Senior Foundry Tooling Design Engineer (Creo & Casting Simulation)

Location: Hodges, SC

Duration: 12 Months

Work Environment: Foundry Manufacturing Facility

Position Overview

We are seeking an experienced Foundry Tooling Design Engineer with strong expertise in casting processes, tooling design, and Creo modeling. This position will be responsible for designing and developing foundry tooling, including patterns and core boxes, supporting casting process improvements, analyzing casting defects, and driving tooling projects from quotation through production.

This is not a general mechanical design role. Candidates must possess hands-on experience in foundry tooling design and casting operations, including no-bake and/or cold-box molding processes.

Key Responsibilities

• Design foundry tooling, patterns, and core boxes using Creo CAD software.
• Develop tooling concepts that improve casting quality and reduce manufacturing lead times.
• Create tooling layouts, parting lines, offsets, clearances, and manufacturing documentation.
• Support RFQ activities and tooling cost estimation.
• Analyze casting defects and implement corrective tooling and process improvements.
• Perform gating and re-gating activities to optimize casting performance.
• Conduct casting simulation and flow analysis using SolidCast or similar software.
• Work closely with manufacturing engineers, pattern makers, tooling suppliers, and production teams.
• Provide technical direction during tooling construction and implementation.
• Support continuous improvement initiatives focused on quality, productivity, and scrap reduction.

Required Qualifications

Foundry Experience (Required)

• Minimum 5 years of foundry engineering, tooling design, or casting engineering experience.
• Strong understanding of:
• Metal casting processes
• No-bake molding
• Cold-box molding
• Gating and riser design
• Casting defect analysis
• Scrap reduction techniques

Tooling Design Experience (Required)

• Experience designing:
• Foundry patterns
• Core boxes
• Tooling assemblies
• Complex cast components
• Strong understanding of:
• Parting lines
• Draft requirements
• Offsets
• Clearances
• Tool build layouts

CAD & Simulation Experience

• Advanced Creo CAD experience (preferred).
• Experience with casting simulation software:
• SolidCast preferred
• MAGMASoft, FLOW-3D Cast, or equivalent will also be considered.
• Ability to read machining drawings and understand GD&T requirements.

Preferred Qualifications

• Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, or related field.
• CNC machining knowledge.
• Experience working directly with tooling suppliers and pattern shops.
• Experience supporting tooling builds from design through production.

Top Skills

1. Foundry Engineering Experience

• Casting processes
• Defect analysis
• Gating design
• No-bake and cold-box systems
• Foundry Tooling Design
• Patterns
• Core boxes
• Tool layouts
• Production-ready tooling design
• Creo & Casting Simulation
• Advanced Creo modeling
• SolidCast or equivalent simulation software

Disqualifiers

Candidates will not be considered if they have:

• No foundry experience
• No casting process experience
• No tooling design experience
• Only general mechanical design experience
• CAD experience without foundry tooling exposure