Senior Foundry Engineer

We are seeking a Senior Foundry Engineer to lead the development and scaling of advanced superalloy casting processes for aerospace and spaceflight applications. This role is ideal for someone with deep foundry experience who wants direct ownership over process development, defect reduction, production readiness, and manufacturing innovation.

You will drive high-temperature casting capability development, beginning with equiaxed superalloy systems and expanding into more advanced solidification technologies over time. The role focuses on process execution, repeatability, yield improvement, and delivering flight-critical hardware quality standards.

Reporting directly to technical leadership, you will play a key role in shaping manufacturing strategy, equipment selection, and next-generation foundry process architecture within a fast-paced startup environment.

Responsibilities

• Lead process development and production readiness for aerospace superalloy castings, including nickel-, cobalt-, and titanium-based alloys.

• Develop and optimize equiaxed casting processes with future expansion into DS and/or single-crystal systems.

• Drive defect reduction, root-cause analysis, and process optimization using SPC, DOE, and first-principles engineering.

• Control solidification behavior, grain structure, porosity, shrinkage, and dimensional stability.

• Collaborate with software and engineering teams on thermal and solidification simulations for gating, risering, and mold design.

• Work across the full foundry process, including shelling, melt practice, pouring, and post-processing.

• Support specification and commissioning of advanced foundry equipment and automation systems.

• Interface with customers and internal teams on material selection, qualification strategy, and production readiness.

• Transition development programs into stable, scalable production processes.

• Bachelor’s, Master’s, or PhD in Materials Science, Metallurgical Engineering, Mechanical Engineering, Aerospace Engineering, or related field.

• 5+ years of foundry experience supporting aerospace, space, or other high-reliability hardware.

• Strong understanding of heat transfer, fluid flow, solidification, phase transformations, and grain structure control.

• Experience with SPC, DOE, and root-cause analysis in casting environments.

• Hands-on foundry floor experience operating equipment and supporting production.

• Ability to thrive in a high-ownership, fast-paced startup environment.

Preferred Experience

• Aerospace superalloy investment casting.

• Directionally solidified (DS) and/or single-crystal casting processes.

• Thermal, fluid flow, or solidification simulation tools.

• AS9100 manufacturing environments.

• Startup or rapid-iteration manufacturing experience.

Base Pay is $120k-$140k plus a full benefit package and 401k match.

Pay Details: $120,000.00 to $140,000.00 per year

Equal Opportunity Employer/Veterans/Disabled