Process Engineer, High Pressure Die Casting (HPDC)

Job DescriptionJob Description

Process Engineer, High Pressure Die Casting (HPDC)

Relocation bonus available for qualified candidates!POSITION SUMMARY

The Process Engineer – HPDC is responsible for developing, optimizing, and maintaining die casting processes to ensure high-quality production, cost efficiency, and operational reliability. This role will lead continuous improvement initiatives, support new product launches, and provide technical expertise in die casting, melting, trimming, and finishing processes.

KEY RESPONSIBILITIES

Process Development & Optimization

• Design, develop, and optimize HPDC processes, including machine parameters, gating design, and cooling systems.
• Analyze process capability and implement improvements to increase yield, reduce scrap, and enhance cycle times.
• Support tooling design and modifications for die casting molds.

Production Support

• Troubleshoot die casting equipment, tooling, and process issues in real time to minimize downtime.
• Develop and maintain standard operating procedures (SOPs) and process documentation.
• Ensure compliance with quality standards (IATF 16949, ISO 9001, etc.).

Quality & Continuous Improvement

• Conduct root cause analysis for quality defects (porosity, cold shuts, flash, etc.) and implement corrective actions.
• Lead continuous improvement initiatives using Lean Manufacturing, Six Sigma, and Kaizen methodologies.
• Collaborate with Quality and Maintenance teams to ensure consistent part quality.

New Product & Launch Support

• Support APQP, PPAP, and new product introduction (NPI) processes for HPDC components.
• Participate in trial runs, parameter development, and validation of new tools.
• Work closely with design engineering to ensure manufacturability.

Safety & Compliance

• Promote and enforce EHS standards in die casting operations.
• Ensure compliance with all company, customer, and regulatory requirements.

QUALIFICATIONS

Education & Experience

• Bachelor's degree in Mechanical, Industrial, Metallurgical, or Manufacturing Engineering (or related field).

• Master's degree but not required

• 3–5 years of experience in high-pressure die casting (HPDC) process engineering.

• Hands-on experience with die casting machines (Bühler, Idra, Toshiba, etc.) and auxiliary equipment.

• Strong background in metallurgy, solidification, and casting defects.

• Familiarity with CAD software (SolidWorks, AutoCAD, CATIA, etc.) and simulation tools (MAGMASoft, ProCAST).

Technical Knowledge & Skills

• Strong analytical and problem-solving skills.

• Knowledge of Lean Manufacturing, Six Sigma, and statistical process control (SPC).

• Ability to manage multiple projects and work cross-functionally.

• Excellent communication skills (written and verbal).

• Proficiency in MS Office (Excel, Word, PowerPoint).

• Technical expertise in die casting processes.

• Results-oriented with a continuous improvement mindset.

• Team player with leadership potential.

• Ability to work in a fast-paced manufacturing environment.

Work Environment

• Manufacturing plant setting with exposure to molten metal, heavy machinery, and high temperatures.

• Personal protective equipment (PPE) required.

The Company is committed to maintaining safe, productive working conditions for our Associates in compliance with applicable laws. Our Background Check Policy contains our guidelines for investigating job candidates' backgrounds as part of our hiring process. The Company's background Check Policy applies to all candidates who go through our hiring process. It also applies to all existing Associates (full time or part-time) who may be subject to random background.

Background checks may include:

? Criminal records - Seven (7) year history

? Credit reports

? Drug testing

? Verification reports (e.g. , previous employment, education, SSN)

? Driving records

? Reference checks

All candidates aren't required to pass every type of background check. Each position has its own requirements. For example, driving records may be relevant to field reliable salespeople and truck drivers, but not to hire a controller. The Company will determine applicable requirements in its absolute discretion. Criminal records don't automatically disqualify candidates from the hiring process, unless they are convicted of serious criminal acts such as aggravated or assault, arson, child abuse, homicide, voluntary manslaughter, murder, rape, robbery or stalking. It should be noted that this list is not all-inclusive and other convictions may warrant disqualification and the Company will make any determination in its absolute discretion. Note that the Human Resources Manager will consider convictions, not arrests, when reviewing a candidate's background check. Human Resources will keep the Company's interests first and foremost when rating the seriousness of any concerns which a background check may uncover. Generally, if Human Resources decides a particular candidate would bring high or unreasonable risk to our Company, they should reject the candidate. Human Resources can call candidates to discuss the results of their background checks. If a candidate answer satisfactorily, they may be considered to be hired to work with our Company, provided that hiring decisions are ultimately in the absolute discretion of the Company.

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