Tooling Engineer

Job Title: Casting & Tooling Engineer

Location: Madison, Wisconsin

Department: Engineering / Manufacturing

Employment Type: Full-Time

Reports To: Engineering Manager / Plant Manager

Salary: $90,000 – $120,000 annually

Position Summary

We are seeking an experienced Casting & Tooling Engineer to join our Madison, WI team in the design, development, and optimization of metal casting processes and tooling. This role combines engineering expertise, metallurgical knowledge, and hands-on problem-solving to ensure high-quality castings while improving efficiency and reducing scrap.

The ideal candidate will have experience in die casting, sand casting, permanent mold casting, or lost foam processes, and may also have a background in metallurgy, process optimization, or tooling design.

Key Responsibilities

• Design and optimize casting tooling, molds, gating systems, and cooling circuits to meet quality and production goals
• Collaborate with simulation teams to perform casting flow and solidification analyses (e.g., MAGMASOFT, EKK, ProCAST)
• Conduct metallurgical evaluations and failure analysis to resolve quality or production issues
• Develop and implement heat treatment and melting processes to ensure proper alloy properties
• Provide CAD support for tooling and part design using software such as Siemens NX, CATIA, Creo, or SolidWorks
• Establish and maintain tooling and process standards to reduce scrap and improve efficiency
• Work with vendors to ensure timely and cost-effective delivery of tooling and components
• Support new product introductions (NPI) and design-for-manufacturability initiatives
• Monitor and maintain quality standards, including metallurgical testing, chemical analysis, and compliance with ASTM and internal standards
• Participate in cross-functional teams with engineering, production, and quality departments

Required Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Materials Science, Metallurgy, or related field
• 5 years of experience in a foundry, metal casting, or tooling engineering environment
• Hands-on experience with one or more of the following: die casting, sand casting, permanent mold, or lost foam
• Proficiency with CAD software (Siemens NX, CATIA, Creo, SolidWorks)
• Familiarity with casting simulation software (MAGMASOFT, EKK, ProCAST, SolidCast)
• Strong knowledge of metallurgical processes, heat treatment, and alloy properties
• Experience in root-cause analysis, process optimization, and quality improvement
• Ability to read and interpret 2D and 3D drawings
• Excellent problem-solving, communication, and teamwork skills

Preferred Qualifications

• Experience managing tooling vendors and manufacturing partners
• Six Sigma or Lean Manufacturing training
• Experience with high-volume automotive or industrial castings
• Knowledge of ASTM standards and NESC/OSHA safety practices

Benefits

• Competitive salary: $90,000 – $120,000
• Health, dental, and vision insurance
• 401(k) with company match
• Paid time off and holidays
• Opportunities for career development and training