Tooling Design Engineer - Cast Iron Foundry

Career Area:
Engineering

Job Description:

Your Work Shapes the World at Caterpillar Inc.

When you join Caterpillar, you're joining a global team who cares not just about the work we do – but also about each other. We are the makers, problem solvers, and future world builders who are creating stronger, more sustainable communities. We don't just talk about progress and innovation here – we make it happen, with our customers, where we work and live. Together, we are building a better world, so we can all enjoy living in it.

About Large Power Systems Division (LPSD)

We design and manufacture a comprehensive lineup of large diesel and natural gas engines, as well as engine components and powertrains.

Job Summary:

Caterpillar is seeking a Tooling Design Engineer – Cast Iron Foundry to join our team in Hodges, South Carolina.

In this role, you will design, develop, build, implement, and validate foundry tooling used to manufacture cast-iron components. You will apply foundry tooling and casting principles to develop effective tooling concepts, including 3D tooling models, patterns, cores, core boxes, core prints, gating systems, filters, risers, and parting lines.

You will work closely with design engineering, the tooling shop, quality, suppliers, and manufacturing teams through tooling design, construction, implementation, and validation. Success in this role requires both 3D modeling capability and practical knowledge of how foundry tooling is designed, constructed, and used to successfully produce castings.

What You Will Do:

- Design and develop 3D models and detailed designs for cast-iron foundry tooling.
- Evaluate casting geometry and determine the cores, core prints, parting lines, gating, risers, filters, and other tooling features required to successfully manufacture the casting.
- Design and support patterns, core boxes, gating systems, and related foundry tooling using established casting and tooling-design principles.
- Apply practical tooling construction knowledge to ensure designs can be effectively built, implemented, and used in production.
- Develop tooling and gating concepts that support proper metal flow, casting quality, manufacturability, and production requirements.
- Partner with design engineering and the tooling shop throughout tooling construction, implementation, and validation.
- Analyze tooling and casting performance and identify solutions to foundry defects, quality concerns, and manufacturing issues.
- Research new materials, manufacturing methods, tooling concepts, and technologies.
- Organize, coordinate, and execute the building, testing, analysis, and validation of prototypes and tooling.
- Develop and document functional requirements and translate them into detailed engineering designs.
- Participate in design reviews and buy-build analysis for tooling and product components.
- Collaborate with supply management and suppliers to support tooling development, quality, and supplier performance.
- Participate in proposal preparation, cost estimates, technical documentation, and engineering reports.

Education:

- Degree from an accredited Engineering or Materials Science curriculum desired

Skills You Must Have:

Foundry Tooling Design:

Working knowledge of foundry tooling-design and construction principles, including the ability to evaluate a casting and develop appropriate patterns, cores, core boxes, core prints, parting lines, gating systems, filters, risers, and other tooling features required to manufacture the component.

3D Modeling & Computer-Aided Design:

Working knowledge of 3D CAD and engineering tools, with the ability to independently develop, analyze, and evaluate 3D foundry-tooling models and detailed tooling designs. Experience with Creo or comparable 3D parametric CAD/modeling software.

Foundry Manufacturing Knowledge:

Working knowledge of casting and foundry manufacturing processes, with the ability to consider molding, core-making, tooling construction, metal flow, manufacturability, and casting quality when developing tooling designs.

Analytical Thinking:

Working knowledge of techniques and tools that promote effective analysis; ability to identify root causes of technical and manufacturing problems and develop effective solutions.

Technical Excellence:

Working knowledge of engineering technologies and their applications; ability to develop and provide practical solutions to significant technical challenges.

Managing Multiple Priorities:

Working knowledge of effective self-management practices; ability to manage multiple concurrent objectives, projects, or activities while making effective decisions regarding priorities and time allocation.

Product Design – Manufacturing:

Working knowledge of manufacturing product-design processes, approaches, tools, and techniques; ability to translate product and manufacturing requirements into effective tooling designs.

Product Design and Development:

Working knowledge of the processes and tools used to design, build, validate, and develop a product or tooling solution from concept through production.

Top Candidates Will Also Have

- Experience with cast-iron foundry tooling design and construction.
- Experience developing 3D tooling models for sand-casting applications.
- Experience determining the cores and core prints required to produce complex castings.
- Experience establishing appropriate mold/tooling parting lines.
- Experience designing gating systems, risers, filters, and other metal-flow features using established foundry principles.
- Experience designing patterns and core boxes.
- Experience with gray iron, ductile iron, or comparable sand-casting applications.
- Knowledge of no-bake and/or cold-box processes.
- Experience with horizontal and/or vertical molding processes.
- Experience identifying, troubleshooting, and resolving foundry defects.
- Strong working knowledge of foundry manufacturing processes and tooling construction.
- Experience with casting simulation software such as MAGMASoft, SolidCast, or comparable casting-simulation software.
- Experience supporting tooling from initial design and construction through implementation, validation, and production.

Additional Information:

- This position is located in Hodges, South Carolina.
- Domestic relocation is available.
- Visa sponsorship is not available.

Final Details:

Please frequently check the email associated with your application, including the junk/spam folder, as this is the primary correspondence method. If you wish to know the status of your application, please use the candidate login on our career website, as it will reflect any updates to your status.

This Job Description is intended as a general guide to the job duties for this position and is intended for the purpose of establishing the specific salary grade. It is not designed to contain or be interpreted as an exhaustive summary of all responsibilities, duties, and effort required of employees assigned to this job. At the discretion of management, this description may be changed at any time to address the evolving needs of the organization. It is expressly not intended to be a comprehensive list of “essential job functions” as that term is defined by the Americans with Disabilities Act.

Summary Pay Range:

$89,210.00 - $133,810.00

Compensation and benefits offered may vary depending on multiple individualized factors, job level, market location, job-related knowledge, skills, individual performance and experience. Please note that salary is only one component of total compensation at Caterpillar.

Benefits: