Die Cast Process Engineer

Job Title: Die Cast Process Engineer (Aluminum Die Casting.) Location: Top Die Casting: 13910 Dearborn Avenue South Beloit Illinois 61080 Department: Engineering / Manufacturing Reports To: Plant Manager Employment Type: Full-Time

Position Summary:

We are seeking a highly skilled and detail-oriented Die Cast Process Engineer with expertise in aluminum die casting to join our manufacturing team. This role is critical to ensuring die casting machines operate at optimal performance, and that casting processes are precisely controlled to produce high-quality, defect-free parts. The ideal candidate will possess deep knowledge in both hydraulic/mechanical/electrical diagnostics and process optimization, with the ability to troubleshoot and resolve issues across a range of equipment and control parameters.

Key Responsibilities:

Process Engineering & Optimization

• Develop, document, and optimize aluminum die casting processes to ensure repeatability, efficiency, and product quality.
• Establish and monitor key process parameters (e.g., metal temperature, shot speed, intensification pressure, lubrication, cooling time, die temperature, etc.).
• Conduct thorough root-cause analysis for process-related defects such as porosity, short shots, flash, cold shuts, blisters, soldering, and dimensional inconsistencies.
• Implement and maintain robust process control strategies (including SPC) to monitor variation and drive continuous improvement.
• Collaborate with Quality and Production teams to validate first article parts and ensure PPAP submissions meet customer requirements.

Machine Diagnostics & Troubleshooting

• Fully diagnose and repair issues related to die casting machinery, including hydraulic, electrical, pneumatic, and mechanical systems.
• Troubleshoot and correct problems with injection systems, shot ends, hydraulic circuits, temperature control units (TCUs), trim presses, spray systems, and robots.
• Interface with maintenance teams to develop preventive maintenance strategies and machine reliability improvements.
• Support die changeovers and ensure machines return to full operational status with proper setup and verification.

Tooling and Die Interaction

• Analyze die performance and provide input on die design to improve casting quality and cycle time.
• Work with tooling engineers and Tool Shop to recommend improvements for tooling life, cooling channel effectiveness, ejection performance, etc.
• Conduct thermal mapping and thermal balance assessments of dies.

Technical Documentation & Training

• Develop and maintain detailed process sheets, work instructions, setup documentation, and machine parameter logs.
• Train operators, technicians, and maintenance personnel on correct process parameters, machine operation, and troubleshooting techniques.
• Support the implementation of Industry 4.0 solutions, including sensors, machine monitoring, and data analytics for process control.

Qualifications:

Education & Experience:

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Metallurgy, or a related technical field preferred.
• 3\u20135+ years of experience in aluminum die casting, preferably in a high-volume production environment.
• In-depth knowledge of high-pressure die casting (HPDC) equipment, processes, and materials.

Technical Skills:

• Strong understanding of die casting machine platforms (e.g., B\u00fchler, Die Cast Press, etc.).
• Ability to read hydraulic/electrical schematics and operate diagnostic tools.
• Familiar with casting simulation software (e.g., Nova-Cast) and process control tools (SPC, DOE, and PFMEA).
• Proficiency with PLC interfaces and industrial automation is a plus.
• Solid knowledge of metallurgy and solidification principles relevant to aluminum alloys.

Soft Skills:

• Excellent problem-solving and analytical thinking.
• Strong communication skills, both verbal and written.
• Collaborative, hands-on, and results-driven mindset.
• Capable of working independently under pressure with attention to detail.

Work Environment & Physical Requirements:

• Manufacturing plant environment with exposure to heat, noise, and aluminum foundry conditions.
• Must be able to occasionally lift parts and equipment (up to 50 lbs.).
• Must be willing to be on the production floor daily and respond to off-shift emergencies or downtime when needed.

Preferred Certifications:

• Six Sigma Green Belt or higher
• Die Casting Society or NADCA technical certification
• OSHA or industrial safety training

Compensation & Benefits:

• Competitive salary based on experience
• Health, Dental, Vision, and Life Insurance
• 401(k)
• Paid time off and holidays
• Continuing education and training support

Apply Now: (email Tyler_Plummer@topdie.com your resume and cover letter.) Join our team and help us produce world-class aluminum die cast components with innovation, precision, and integrity.