Senior Casting Simulation Engineer

LeClaire Manufacturing is a leader in aluminum casting and machining, specializing in high-precision, high-quality components. We are expanding our simulation and process development capabilities to improve efficiency, quality, and innovation in our casting processes. 

Job Overview 

We are seeking a Senior Casting Simulation Engineer to optimize and refine our foundry operations using MagmaSoft and other simulation tools. This role bridges engineering, process development, and quality—ensuring robust casting designs and efficient manufacturing solutions. 

This position is ideal for an experienced foundry engineer with a background in green sand or permanent mold casting, project management, process analytics, and quality control. 

Key Responsibilities 

• Simulation & Modeling: Utilize MagmaSoft to analyze and optimize casting processes, including gating, solidification, and defect reduction.
• Process Development: Collaborate with the foundry team to implement simulation-driven improvements, enhancing efficiency and reducing scrap rates.
• Quality & Troubleshooting: Investigate casting defects and apply data analytics to improve process stability and yield.
• Project Management: Lead simulation-driven improvement initiatives, working cross-functionally with engineering, production, and quality teams.
• Tooling & Design Support: Assist with the development of 3D models and core designs to enhance manufacturability.
• Data & Analytics: Apply process mapping, data analytics, and statistical methods to monitor and improve casting performance.
• Mentorship & Training: Support engineers, technicians, and co-op students in understanding and applying casting simulation techniques.

Qualifications 

• Bachelor’s Degree in Engineering, Metallurgy, or Industrial Technology (or equivalent experience).
• 3 years of foundry engineering experience, preferably in green sand or permanent mold aluminum casting.
• Proficiency in MagmaSoft or similar casting simulation software.
• Strong background in process troubleshooting, defect analysis, and quality improvement.
• Experience with project management, data analytics, and Six Sigma principles.
• Knowledge of 3D modeling, CAD software, and process automation is a plus.

Why Join Us? 

• Opportunity to work with cutting-edge casting simulation and process development tools.
• Potential for involvement in aerospace projects through our G4 Advanced Manufacturing sister company.
• A collaborative team that values innovation, process improvement, and engineering excellence.

If you’re looking for a challenging and rewarding role in advanced casting simulation and process optimization, we’d love to hear from you!