Principal Casting Engineer

Beehive Industries is dedicated to Powering American Defense by revolutionizing the design, development, and delivery of jet propulsion systems to support the warfighter. Through the integration of additive manufacturing, the company aims to meet the growing and urgent needs for unmanned aerial defense by dramatically improving a jet engine’s speed to market, fuel efficiency, and cost. Founded in 2020, the company is headquartered in Centennial, Colorado, with additional facilities in Knoxville, Tennessee, Loveland Ohio, and Mount Vernon, Ohio. Beehive is committed to grow and advance the defense industrial base while manufacturing exclusively in the USA. This role will be located at our Loveland, Ohio facility.

About the Role

We are looking for a Principal Casting Engineer to serve as the lead technical authority for our internal casting needs. This is a hands-on, high-impact role dedicated entirely to ensuring Beehive’s innovative engine platforms have a fast, reliable, and vertically integrated path from design to flight-ready hardware. You will be the technical lead responsible for the internal casting of Beehive’s proprietary engine components. You will work as a core member of the team to translate complex engine designs into successful, high-integrity cast components. This role is critical to scaling precision casting operations, introducing new technologies, and supporting cross-functional product innovation. The ideal candidate will have a strong command of metallurgical science, casting simulation, defect analysis, and automation opportunities, with a track record of delivering complex components at scale.

Responsibilities

• Technical Leadership
  • Act as the technical authority for the casting process, leading process definition, control, and continuous improvement across all programs
  • Mentor engineers in casting fundamentals, advanced metallurgy, and best practices
  • Review and approve gating/riser designs, shell configurations, and critical process documents for development and production programs
• Process Innovation & Development
  • Lead development of next-generation casting processes including single crystal (SX), directionally solidified (DS), equiaxed (EQ), and additive-enabled casting workflows
  • Develop robust casting parameters for nickel-based superalloys, titanium, cobalt, and advanced steels in vacuum or inert environments
• Simulation & Data-Driven Engineering
  • Oversee use of casting simulation tools (e.g., MAGMASOFT, ProCAST) to predict defects, optimize gating, and reduce trial iterations
  • Drive adoption of data analytics and digital twins to correlate process parameters with quality outcomes and productivity KPIs
• Quality & Compliance
  • Define critical-to-quality (CTQ) metrics and ensure compliance with AS9100, NADCAP, and program-specific specifications
  • Lead complex RCCA investigations using 8D, FMEA, and Six Sigma methodologies
  • Interface directly with stakeholders as the SME on casting process capability and conformance

Requirements

• Bachelor’s or master’s degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, or equivalent
• 15+ years of progressive experience in precision investment casting, with at least 5 years in a principal or technical leadership capacity
• Deep expertise in casting of superalloys, vacuum melting, ceramic shell chemistry, thermal control, and defect prevention
• Demonstrated proficiency in casting simulation, statistical process control, and technical documentation
• Experience with high-performance industries such as aerospace, defense, or IGT is strongly preferred
• The ability to obtain and maintain a U.S. government-issued security clearance is required. U.S. Citizenship is required, as only U.S. Citizens are eligible for a security clearance

Nice to Have

• Knowledge of automated foundry systems, robotics, and in-situ inspection technologies
• Experience integrating additive manufacturing into the casting workflow (e.g., printed wax/ceramic patterns, hybrid cores)
• Strong business acumen with the ability to influence capital investment and product cost models
• Thought leadership via industry publications, patents, or conference presentations

Benefits

• Comprehensive benefits package including group Medical, Dental, Life, and Short and Long-Term Disability coverage from day one
• Generous 401(k) Retirement Savings Plan with a Company match
• Bonus eligibility for every role
• Equity in the company