Company Description
Protocast, 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 Summary
The 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 Responsibilities
- Lead the launch of new tooling and castings in tilt pour and low-pressure permanent mold processes
- Serve as the first operator for all new jobs, developing and refining process parameters to achieve optimal quality and efficiency
- Establish and document critical process settings including temperatures, fill rates, cycle times, and cooling methods
- Troubleshoot casting defects (porosity, cold shuts, misruns, etc.) and implement corrective actions
- Collaborate with tooling, quality, and production teams to ensure successful job launches
- Develop standardized work instructions, process sheets, and visual aids for production use
- Train shift leads and production personnel on new processes, ensuring understanding and adherence to standards
- Monitor initial production runs and provide hands-on support to stabilize processes
- Drive continuous improvement in casting performance, yield, and cycle time
- Support root cause analysis and corrective action efforts for quality or process issues
- Ensure all processes comply with safety, environmental, and company standards
Qualifications
- Bachelor’s degree in Engineering (Mechanical, Metallurgical, Manufacturing, or related field) preferred but not required
- 2+ years of experience in aluminum casting preferred, preferably in permanent mold operations
- Experience with process development, tooling launches, and production ramp-up
- Ability to identify and resolve casting defects and process variability
- Strong hands-on, shop-floor oriented mindset
- Excellent communication and training skills
- Ability to create clear and effective work instructions and documentation
Key Skills & Competencies
- Process development and optimization
- Problem-solving and root cause analysis
- Technical leadership during production launches
- Training and knowledge transfer
- Attention to detail and process discipline
- Cross-functional collaboration
- Must work well with people and lead a team
Work Environment
- Foundry environment with exposure to heat, noise, and industrial equipment
- Significant time spent on the production floor during job launches and process validation
Success Metrics
- Successful launch of new tools on time and within quality targets
- Reduction in scrap and rework during initial production runs
- Stability and repeatability of established processes
- Effectiveness of training and clarity of work instructions
- Continuous improvement in yield and cycle efficiency
