Senior Process Engineer - Casting

At General Motors, our product teams are redefining mobility. Through a human-centered design process, we create vehicles and experiences that are designed not just to be seen, but to be felt. We’re turning today’s impossible into tomorrow’s standard —from breakthrough hardware and battery systems to intuitive design, intelligent software, and next-generation safety and entertainment features.

Every day, our products move millions of peopleas we aim to make driving safer, smarter, and more connected, shaping the future of transportation on a global scale.

The Launch Process Engineering Team excels in the development, testing, implementation and execution of new casting programs, platforms and technology. This group is unique in that by working with and across multiple levels of the GM technical groups, vendors and suppliers, the complex problems of casting projects are developed into controlled manufacturing processes.

The Specific Purpose of this position is to perform casting manufacturing projects by following a systematic engineering process of evaluation, development, validations, technology transfer leading into and supporting the production launch and processing. Specifically responsible and directly involved in the development of manufacturing processes, equipment, tooling and alternatives, sequences, operations, utilizations for the production of castings.

• Ability to work individually on specific programs yet collaboratively with Launch Team, QC, Design, Tooling, and other support groups
• Demonstrate technical knowledge of foundry processes and ability to apply concepts in a manufacturing environment
• Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering procedures
• Support testing and installations of equipment, tooling and technologies both on and off site
• Lead, support and present the analysis of casting defects
• Assist in process, tooling and equipment testing, troubleshooting and implementations
• Develop process documentation, Process flow diagrams, PCP, PFMEA, TIS, and related technical documents as necessary for a program launch
• Analyze first time quality data and optimize processes using DOE, Red X, and related statistical tools
• Perform both Non and destructive testing procedures for casting investigation and analysis (leak testing, x ray, CT, thermal, lab specimen prep, chemistry, density, mechanical, etc)
• On site work, working on shop floor, hands on equipment, understanding of casting shop activity.

• 3+ years of professional experience in a manufacturing environment
• Demonstrated knowledge of foundry processes and ability to apply casting concepts in a manufacturing environment
• 2+ years of professional experience in Low Pressure Die Casting, Precision Sand, Semi Permanent Mold or similar, tooling, process, quality, or project management experience.
• Knowledge of process engineering procedures and disciplines
• Basic knowledge of Magma, Flow 3D, simulation software
• Basic knowledge of NX or Catia or any 3D design software
• Effective and functional knowledge of aluminum chemistry, heat treat, metallurgical processes
• Demonstrated understanding of mechanical concepts involving machine design, process equipment, tooling, and secondary post processing
• BS degree (engineering, metallurgical, computer science) or equivalent experience is required

• Training in aluminum metallurgy
• Prior experience in Low Pressure Die Casting, Precision Sand or Semi Permanent Mold
• Prior experience in injection molds
• Prior experience in castings or Giga/Structural castings
• Training in flow…