Process Engineer

Cast Alum is an internationally acclaimed aluminium die casting and machining centre located in Welshpool, UK. The site was a Greenfield development in the winter of , serving one customer only.

20 years on, the company supplies parts to the UK, Europe, Canada, and Mexico. We have grown from die casting aluminium parts only to supplying a range of products (using high pressure die casting, squeeze die casting, and machining). We can supply aluminium components as cast, cast & machined, or assembled & tested according to the needs of our customers.

The Process Engineer is the on-shift technical authority responsible for leading all process-related decision making across the high-pressure die casting (HPDC) department. The role ensures casting processes are stable, capable, and optimised to deliver quality, safety, and productivity targets. Working closely with Process Technicians & the Production, Maintenance, Toolroom and Quality departments. The Process Engineer provides advanced technical support, root cause analysis, and methodical process optimisation using recognised die casting methodologies.

Key Responsibilities

Leadership & Decision Making

• Act as the highest level of on-shift technical decision maker for all HPDC processes.
• Provide direction to Process Technicians on process adjustments, die changes, and fault diagnosis.
• Lead start-ups, restarts, die trials, parameter validation, and approval of first-off samples.
• Set up and be involved in all automation processes for Die cast Cells. (6 axis robots, Conveyor systems)
• Ensure that all process changes are controlled, logged, and aligned with engineering standards.
• Make safe, effective decisions under time pressure to maintain production and minimise downtime.

Work closely with the Process Supervisor and Manager on company objectives.

Skills, Experience & Qualifications

• Strong background in high-pressure die casting (HPDC), ideally in automotive-grade environments.
• Proven experience analysing shot profiles, thermal behaviour, and casting defects.
• Ability to lead technical decision-making and guide teams under pressure.
• Strong understanding of gating, venting, vacuum systems, die cooling, and metal flow dynamics.
• Proven problem-solving ability using structured methods and data-driven decision making.
• Competent with shot monitoring software, SPC analysis, and process documentation.
• Degree or HNC/HND in Mechanical, Manufacturing, Metallurgy, or related engineering field.
• Experience with aluminium alloys.
• Familiarity with DOE methods, Six Sigma, and statistical tools.
• Strong understanding of hydraulic systems, accumulators, and servo-controlled shot systems.
• Experience in continuous improvement programs (Kaizen, Lean).
• KUKA and ABB 6 axis robot knowledge / experience.