NPI Process Engineer Casting
Position Overview
The NPI Casting Process Engineer drives casting optimization and process development during the early stages of new product integration; translating complex design intent into manufacturable, high-quality casting solutions. This role works cross-functionally with CAD Developers, Project Leads, and Manufacturing Engineers to ideate and refine sprue systems, leveraging an in-depth understanding of fluid dynamics, solidification behavior, shrinkage compensation, and defect mitigation strategies.
Key Accountabilities
Utilize advanced casting simulation software to evaluate variables that impact casting quality and reduce scrap rates.
Work closely with CAD and Engineering teams to iterate on casting designs, balancing manufacturability, mechanical properties, and aesthetic requirements to meet both engineering and design expectations.
Manage trial casting activities by coordinating with cross-functional teams to create detailed work orders, schedule test runs, and define acceptance criteria for prototype castings.
Lead the hands-on evaluation of cast parts, performing dimensional inspections, non-destructive testing (NDT), and other analysis to verify accuracy and conformity to specifications.
Capture and analyze process data to diagnose deviations and recommend iterative adjustments to sprue design, tree setup, or casting parameters.
Document findings and communicate results effectively to stakeholders to support timely decision-making and minimize development cycle time.
Apply lean manufacturing and quality tools to identify inefficiencies, bottlenecks, and sources of casting defects early in the NPI process.
Use data-driven approaches to prioritize improvements and implement corrective actions that enhance yield, reduce cycle time, and improve overall process robustness.
Continuously monitor process metrics during ramp-up phases, driving a culture of continuous improvement and ensuring sustainable quality performance.
Drive continuous innovation and technology adoption by researching and evaluating emerging casting technologies, materials, and process improvements.
Promote a forward-thinking mindset that keeps the casting process at the forefront of industry advancements and supports long-term competitive advantage.
Required Qualifications
Bachelor’s degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, or a related discipline; or equivalent hands-on experience in casting process development within the jewelry industry.
Strong ability to analyze and solve complex casting process challenges using Root Cause Analysis methods.
Experience managing multiple projects simultaneously in a fast-paced New Product Integration (NPI) environment, with strong organizational and time management skills.
Understanding of metallurgical fundamentals relevant to precious metals.
Ability to perform hands-on inspections of cast parts.
Working knowledge of CAD software, particularly tools like Rhino and/or Solid works.
Excellent communication skills (written, verbal, and presentation) to effectively collaborate with cross-functional teams including CAD, manufacturing, and quality.
Advanced proficiency in Microsoft Office Suite, particularly Excel.
Proficiency in statistical analysis and process control technique.
Preferred Qualifications
Hands-on experience with simulation software relevant to manufacturing.
Familiarity with modern jewelry manufacturing techniques.
Direct experience in jewelry casting processes, including investment casting.
Familiarity with project management tools such as Wrike.
Knowledge of advanced data tools PDM/PLM, ERP, and Tulip systems.
Experience supporting product launches and production ramp-up.