Manufacturing Process Engineer

Company DescriptionProtocast, based in Denver, CO, is a foundry and machine shop that specializes in high-quality prototypes and production parts, utilizing a variety of manufacturing processes including both sand and permanent mold casting. Protocast serves industries including automotive, defense, electronics, medical, and industrial equipment. Protocast's engineers work closely with clients from part design to production, ensuring optimized manufacturability and efficient delivery for quantities ranging from 50 to 50,000 pieces.Position SummaryThe Process Engineer is responsible for the development, launch, and optimization of new casting processes within a permanent mold foundry. This role leads the initial execution of new tooling in both tilt pour and low-pressure casting machines, establishing robust, repeatable processes that meet quality, safety, and production targets. The Process Engineer serves as the technical owner of new job launches and ensures successful handoff to production through training and documentation.Key ResponsibilitiesLead the launch of new tooling and castings in tilt pour and low-pressure permanent mold processesServe as the first operator for all new jobs, developing and refining process parameters to achieve optimal quality and efficiencyEstablish and document critical process settings including temperatures, fill rates, cycle times, and cooling methodsTroubleshoot casting defects (porosity, cold shuts, misruns, etc.) and implement corrective actionsCollaborate with tooling, quality, and production teams to ensure successful job launchesDevelop standardized work instructions, process sheets, and visual aids for production useTrain shift leads and production personnel on new processes, ensuring understanding and adherence to standardsMonitor initial production runs and provide hands-on support to stabilize processesDrive continuous improvement in casting performance, yield, and cycle timeSupport root cause analysis and corrective action efforts for quality or process issuesEnsure all processes comply with safety, environmental, and company standardsQualificationsBachelor's degree in Engineering (Mechanical, Metallurgical, Manufacturing, or related field) preferred but not required2+ years of experience in aluminum casting preferred, preferably in permanent mold operationsExperience with process development, tooling launches, and production ramp-upAbility to identify and resolve casting defects and process variabilityStrong hands-on, shop-floor oriented mindsetExcellent communication and training skillsAbility to create clear and effective work instructions and documentationKey Skills & CompetenciesProcess development and optimizationProblem-solving and root cause analysisTechnical leadership during production launchesTraining and knowledge transferAttention to detail and process disciplineCross-functional collaborationMust work well with people and lead a teamWork EnvironmentFoundry environment with exposure to heat, noise, and industrial equipmentSignificant time spent on the production floor during job launches and process validationSuccess MetricsSuccessful launch of new tools on time and within quality targetsReduction in scrap and rework during initial production runsStability and repeatability of established processesEffectiveness of training and clarity of work instructionsContinuous improvement in yield and cycle efficiency

Created: 2026-05-08