Senior Foundry Tooling Design Engineer (Creo & Casting Simulation

Location: Hodges, SC

Duration: 12 Months

Work Environment: Foundry Manufacturing Facility

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.

• 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 Solid Cast 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.

• Minimum 5+ years of foundry engineering, tooling design, or casting engineering experience.
• Strong understanding of:
• No-bake molding

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

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

• 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.

• Foundry Engineering Experience
• Casting processes
• Defect analysis
• No-bake and cold-box systems
• Foundry Tooling Design
• Patterns
• Core boxes
• Creo & Casting Simulation
• Advanced Creo modeling
• Solid Cast or equivalent simulation software

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