Senior Process Engineer - Investment Casting

An early-stage, well-funded advanced manufacturing start-up is building a next-generation, fully integrated digital foundry focused on high-performance metal castings for aerospace and industrial applications. By combining additive manufacturing with software-driven process control, the company is redefining speed, cost, and quality in precision casting.

With strong commercial traction and initial parts already delivered, the team is now scaling its foundry capabilities and looking for a senior engineer to take ownership of high-temperature alloy casting processes from development through production.

This is a hands-on, high-ownership position focused on developing and scaling superalloy investment casting processes for flight‑critical hardware. You will own the full casting lifecycle — from melt to finished part — with a focus on process control, defect reduction, and repeatability.

You’ll work closely with leadership and cross‑functional teams to define process architecture, select equipment, and build a modern foundry environment from the ground up.

• Own development and scale‑up of high‑temperature alloy casting processes (Ni‑, Co‑, Ti‑based systems)
• Drive casting from melt through solidification, inspection, and acceptance
• Identify and eliminate defects through root‑cause analysis and process improvement
• Apply physics‑based understanding of heat transfer, fluid flow, and solidification to optimize outcomes
• Develop and tighten process windows using SPC and DOE methodologies
• Collaborate with software teams to inform simulation‑driven casting design (gating, risering, thermal control)
• Partner with engineering teams to specify and commission foundry equipment
• Support transition from development into stable, repeatable production
• Interface with customers on technical discussions related to casting strategy and qualification

• 5+ years of hands‑on experience in investment casting (aerospace or high‑spec applications)
• Strong first‑principles understanding of casting physics and metallurgy
• Proven experience with defect analysis and process improvement
• Direct foundry floor experience (not purely theoretical or simulation‑based)
• Ability to operate in a fast‑paced, high‑ownership start‑up environment

• Superalloy casting for aerospace or defense applications
• Exposure to directionally solidified or single‑crystal processes
• Experience across multiple foundry stages (patterns, shelling, melt, post‑processing)
• Familiarity with simulation tools for thermal/solidification modeling
• Experience in AS9100 or similarly regulated environments
• Background in startup or rapid‑iteration manufacturing settings

• Direct ownership over critical manufacturing processes
• Opportunity to build and shape a modern foundry from first principles
• High‑impact role in advancing next‑generation aerospace hardware
• Small, highly technical team with significant autonomy
• Competitive salary and meaningful early‑stage equity