Tool Design Engineer

Job Summary Designs and develops foundry tooling for a sand casting operation, with a focus on patterns, pattern plates, and core boxes. This role uses MAGMA casting simulation to model mold filling and solidification, and designs new plates to replace legacy tooling that contributes to mold shift and poor yield. The engineer works with the Foundry, South Floor, Tool Room, and CNC teams to improve casting quality, yield, and throughput. Job Duties Design and develop foundry tooling for sand casting, including patterns, match plates, cope and drag plates, core boxes, and related fixturesRun MAGMA casting process simulations of mold filling, solidification, and cooling to predict and prevent defects such as shrinkage, porosity, misruns, and cold shutsDesign and optimize gating, runner, riser, and feeding systems, and validate them through simulation and trial poursLead the redesign of legacy pattern plates that cause mold shift and poor yield, including planning and managing the changeover to new toolingCreate 3D models, drawings, and CNC-ready models, and work with CNC programmers and the Tool Room so tooling is machined accurately and efficientlyApply pattern allowances (shrinkage, draft, machining stock), parting line placement, and GD&T to all tooling designsLead first-article and trial runs for new or modified tooling; analyze casting defects and make design correctionsTrack scrap, yield, and mold shift results before and after tooling changes, and report on improvementsMaintain tooling records, revision control, and pattern and plate documentationProvide design-for-casting input to NPD and Product Engineering on new partsCollaborate with team members to increase overall throughputComplete all necessary documents fully and accuratelyAdhere to 5S standards (e.g., maintain cleanliness of work area, etc.)Follow all Safety, Environmental and Quality policies and proceduresPerform other duties as assigned Experience and Education Bachelor's degree in Mechanical, Manufacturing, or Metallurgical Engineering, or equivalent experience3+ years of experience in tooling or pattern design for a sand casting foundryHands-on experience with MAGMA (MAGMASOFT) or similar casting simulation softwareProficiency in 3D CAD software (SolidWorks or similar) and creating production drawingsWorking knowledge of CNC machining and design for manufacturabilityPerform work under minimal supervision and refer only the most complex issues to higher level staff Competencies/ Skills Ability to set up, run, and interpret MAGMA casting simulationsStrong knowledge of the sand casting process, including molding, coring, gating, risering, and shrinkage3D modeling, detailed drawing, and GD&T skillsStrong problem-solving skills, including root cause analysis tools (5 Why, fishbone, 8D)Ability to analyze scrap and yield data, manage multiple tooling projects, and meet deadlinesStrong verbal, written, and interpersonal communication skills