Design Engineer 4

Client is seeking an experienced Design Engineer 4 to join its Foundry Engineering team in Hodges, SC. This role focuses on designing foundry tooling using Creo for No-Bake and Cold Box molding processes while supporting casting quality improvements, tooling optimization, and manufacturing efficiency. The ideal candidate will possess strong foundry engineering knowledge, tooling design expertise, CAD proficiency, and casting simulation experience. This position offers the opportunity to work closely with manufacturing engineers, pattern makers, programmers, and suppliers to develop high-quality tooling solutions that improve productivity and reduce lead times., * Design foundry tooling using Creo following Caterpillar standards and best practices.

• Design and develop patterns, core boxes, and foundry tooling for No-Bake and Cold Box molding processes.
• Prepare tooling quotations (RFQs) and support tooling procurement activities.
• Analyze casting defects, identify root causes, and implement corrective tooling modifications.
• Perform tooling redesign, re-gating, and process improvements to enhance casting quality.
• Conduct casting flow simulations using SolidCast to validate tooling designs.
• Develop complex 3D CAD models and detailed manufacturing drawings.
• Collaborate with manufacturing engineers, tool designers, programmers, and pattern makers throughout tooling development.
• Coordinate with suppliers during tooling build projects and monitor progress.
• Interpret machining drawings and apply GD&T principles during tooling design.
• Support foundry process improvements focused on quality, productivity, and lead-time reduction.
• Provide technical guidance during tooling construction and shop-floor implementation.

• Associate’s or Bachelor’s Degree in Mechanical Engineering or a related engineering discipline.
• Minimum 5 years of relevant foundry engineering and tooling design experience.

• Strong experience designing foundry tooling for:

• No-Bake Process
• Cold Box Process
• Hands-on experience with Creo CAD software.

• Experience designing:

• Pattern tooling
• Core boxes
• Complex foundry tooling assemblies

• Strong understanding of:

• Casting processes
• Tool layouts
• Parting lines
• Offsets
• Clearances
• Experience performing casting simulations using SolidCast (preferred).
• Ability to analyze and resolve casting scrap and quality issues.
• Strong knowledge of machining drawings and GD&T.
• Excellent communication and collaboration skills.

Preferred Qualifications

• CNC Milling knowledge.
• Experience working directly with foundry suppliers.
• Experience leading tooling build activities.
• Manufacturing process improvement experience.
• Strong problem-solving and analytical skills.

Required Technical Skills

• Creo (Preferred CAD Platform)
• SolidCast (Casting Simulation)
• CAD Modeling
• Pattern & Core Box Design
• Foundry Tooling Design
• Casting Process Knowledge
• No-Bake Molding
• Cold Box Molding
• GD&T
• Manufacturing Drawings
• Casting Defect Analysis
• RFQ Preparation
• Tool Layout Design

Soft Skills

• Excellent verbal and written communication.
• Strong problem-solving ability.
• Ability to work independently.
• Strong collaboration with cross-functional teams.
• Ability to manage supplier interactions.
• Effective planning and organizational skills.

Work Environment

• Foundry production environment.
• Manufacturing shop floor.
• Office-based CAD design work.
• Exposure to hot summers and cold winters in foundry operations.

Top 3 Required Skills * Foundry Engineering Experience

• Tool quotation
• Casting defect analysis
• No-Bake & Cold Box processes

• Foundry Tooling Design

• Pattern tooling
• Core box design
• Complex CAD modeling
• Tool layouts and clearances

• Creo & SolidCast

• Advanced Creo modeling
• Casting flow simulation
• Tool validation