Role & responsibilities

Casting Process Expertise

- Develop and optimize HPDC, LPDC, GDC, and Sand Casting processes.
- Establish robust manufacturing processes for current product development.
- Improve casting yield and reduce process variation.

Tooling Development & Validation

- Review tooling designs for manufacturability.
- Verify and validate new casting tools and dies.
- Conduct tool trials and production readiness assessments.
- Coordinate tooling modifications and improvements.

Tool Cost Estimation

- Prepare cost estimates for: PDC Dies, GDC Dies, Sand Casting Patterns, Core Boxes
- Analyze material, machining, heat treatment, and development costs.
- Support RFQ, budgeting, and supplier negotiations.

Tool Audit & Tool Life Monitoring

- Conduct periodic tool audits.
- Verify tool condition against design requirements.
- Assess die wear, cooling channels, vents, ejector systems, and parting line conditions.
- Monitor tool life and recommend preventive maintenance.
- Identify tooling improvements to reduce downtime and casting defects.
- Prepare tool audit reports with action plans.
- Ensure tooling inventory and maintenance records are updated.

Casting Defect Analysis & Resolution Analyze and resolve:

- Gas Porosity

- Shrinkage Porosity

- Blow Holes





- Cold Shuts

- Misruns

- Cracks

- Inclusions

- Flash

- Die Mismatch

- Soldering and Die Erosion
- Perform Root Cause Analysis (RCA).
- Implement corrective and preventive actions.
- Improve existing dies to eliminate recurring defects.

Other skills:

- Ability to read engineering drawings and CAD models. Preferred SolidWorks.
- Experience in Product data management software
- BOM management
- Tolerance Stack up analysis,

Preferred Experience

- 8-15 years in Foundry, Die Casting, or Casting Tool Development.
- Automotive, Industrial Equipment, Pump, Valve
- Experience working with tooling suppliers and foundries.

Preferred candidate profile

- Bachelors/Masters in Mechanical Engineering
- 5+ years in product design & development

kills:

- Knowledge of manufacturing processes & materials
- Tools: SolidWorks, AutoCAD, SAP ERP, PDM, Nano CAD, MS Office
- Strong project management & problem-solving skills
- Experience in electro-mechanical system integration

Key Competencies:

- Project planning & execution
- Communication & teamwork
- Vendor coordination
- Training & mentoring
- Adaptability & ownership

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