Process Engineer in Shirley, Indiana at Tech Castings LLC

About Tech Castings:

Tech Castings is a leader in Aerospace Investment Casting with a steadfast commitment to investing in the best business tools and equipment available. We have grown revenue in every year of our existence since 2011, working with OEM’s including GE Aerospace, Rolls Royce and Honeywell, and recently completed a 5-million-dollar expansion.

Position Summary

The Investment Casting Process Engineer supports the development, optimization, and sustainment of manufacturing processes for precision aerospace components produced via the investment casting method. Working closely with senior engineers and production leadership, this role focuses on process stability, casting quality, and continuous improvement across wax, shell, vacuum and air casting, and finishing operations with a primary emphasis on nickel and cobalt-based superalloy systems.

Key Responsibilities

Process Support & Optimization

• Support development and validation of casting processes for new and existing aerospace components, including gating/riser design, shell system parameters, and vacuum melt/pour parameters
• Maintain and update process control plans, work instructions, and inspection criteria
• Assist in root cause analysis and corrective action for casting defects common to superalloy systems shrinkage porosity, hot tearing, grain defects, ceramic inclusion, and surface oxidation
• Track and analyze scrap and rework data to identify yield improvement opportunities

Technical & Production Support

• Provide engineering support to wax, shell, vacuum furnace, and finishing operations on a day-to-day basis
• Troubleshoot process deviations related to dimensional non-conformance, surface finish, and metallurgical properties
• Interface with metallurgical lab for chemistry verification, microstructure review, and mechanical property evaluation (tensile, stress rupture, hardness)
• Support fluorescent penetrant inspection (FPI) and X-ray review processes

New Product Introduction (NPI)

• Participate in design-for-manufacturability (DFM) reviews for new aerospace castings
• Assist in quoting new parts for customers including cost estimating, specification review, gating design, and tooling requirements
• Assist in developing tooling specifications and coordinating wax die design, build, and qualification with tooling suppliers
• Support first article inspection (FAI) and AS9102 documentation packages

Quality & Compliance

• Support NADCAP and AS9100 audit preparation and surveillance activities
• Maintain familiarity with customer-specific requirements and aerospace material specifications (AMS, PWA, GE, Rolls-Royce, etc.)
• Assist with SPC implementation and control chart monitoring for critical casting parameters

Continuous Improvement

• Participate in Lean and Kaizen events within the foundry
• Contribute to PFMEA updates and process risk reviews
• Collaborate with maintenance on PM programs for vacuum induction melting (VIM) furnaces, autoclaves, and shell room equipment

Qualifications

Required

• Bachelor's degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, or related field
• 1–4 years of experience in investment casting, precision casting, or aerospace manufacturing (internship or co-op experience in a foundry environment considered)
• Basic understanding of superalloy metallurgy (nickel- and cobalt-based alloys, solidification behavior, oxidation resistance)
• Familiarity with GD&T and CMM-based and/or laser dimensional inspection
• Familiarity with casting and machining blueprints
• Capability in 3D drawing, component design, and model editing (i.e. SolidWorks)
• Strong analytical and problem-solving skills

Preferred

• Hands-on experience with vacuum induction and air melting operations
• Basic understanding of superalloy metallurgy (nickel- and cobalt-based alloys, solidification behavior, oxidation resistance)
• Familiarity with ceramic shell systems used in superalloy casting (zircon face coats, alumina/silica backup systems)
• Exposure to NADCAP or AS9100 quality environments
• Six Sigma Green Belt or coursework toward certification

Work Environment

This position operates in both office and active foundry settings. Regular exposure to vacuum furnace operations, high-temperature environments, ceramic particulate, and chemical shell materials is expected. Full PPE compliance is required. Occasional travel to customer facilities or suppliers may be required.

Competencies

• Detail-oriented with solid organizational and documentation habits
• Eagerness to develop deep technical expertise in superalloy casting
• Collaborative mindset with ability to work across engineering, quality, and production teams
• Ability to communicate technical findings clearly to both engineers and operators