Process Engineer
Posted 6 days ago by CastAlum
Negotiable
Undetermined
Undetermined
Welshpool, Wales, United Kingdom
Summary: The Process Engineer at CastAlum serves as the on-shift technical authority for the high-pressure die casting department, ensuring optimal casting processes to meet quality, safety, and productivity targets. This role involves leading technical decision-making, providing advanced support, and optimizing processes in collaboration with various departments. The engineer will also manage automation processes and ensure compliance with engineering standards. A strong background in high-pressure die casting, particularly in automotive environments, is essential for success in this position.
Key Responsibilities:
- Lead all process-related decision making across the high-pressure die casting (HPDC) department.
- Ensure casting processes are stable, capable, and optimized for quality, safety, and productivity.
- Provide advanced technical support, root cause analysis, and methodical process optimization.
- Act as the highest level of on-shift technical decision maker for all HPDC processes.
- Direct Process Technicians on process adjustments, die changes, and fault diagnosis.
- Lead start-ups, restarts, die trials, parameter validation, and approval of first-off samples.
- Set up and manage automation processes for Die cast Cells, including 6 axis robots and conveyor systems.
- Control and log all process changes in alignment with engineering standards.
- Make safe, effective decisions under time pressure to maintain production and minimize downtime.
- Collaborate with the Process Supervisor and Manager on company objectives.
Key Skills:
- Strong background in high-pressure die casting (HPDC), ideally in automotive-grade environments.
- Proven experience analyzing shot profiles, thermal behavior, and casting defects.
- Ability to lead technical decision-making and guide teams under pressure.
- Strong understanding of gating, venting, vacuum systems, die cooling, and metal flow dynamics.
- Proven problem-solving ability using structured methods and data-driven decision making.
- Competent with shot monitoring software, SPC analysis, and process documentation.
- Degree or HNC/HND in Mechanical, Manufacturing, Metallurgy, or related engineering field (desirable).
- Experience with aluminium alloys and familiarity with DOE methods, Six Sigma, and statistical tools (desirable).
- Strong understanding of hydraulic systems, accumulators, and servo-controlled shot systems (desirable).
- Experience in continuous improvement programs (Kaizen, Lean) and KUKA and ABB 6 axis robot knowledge/experience (desirable).
Salary (Rate): undetermined
City: Welshpool
Country: United Kingdom
Working Arrangements: undetermined
IR35 Status: undetermined
Seniority Level: undetermined
Industry: Other
Company Description Job Description Key Responsibilities Qualifications, Skills & Experience Additional Information CastAlum is an internationally acclaimed aluminium die casting and machining centre located in Welshpool, UK. The site was a Greenfield development in the winter of 2000-2001, serving one customer only. 20 years on, the company supplies parts to the UK, Europe, Canada, and Mexico. We have grown from die casting aluminium parts only to supplying a range of products (using high pressure die casting, squeeze die casting, and machining). We can supply aluminium components as cast, cast & machined, or assembled & tested according to the needs of our customers.
The Process Engineer is the on-shift technical authority responsible for leading all process-related decision making across the high-pressure die casting (HPDC) department. The role ensures casting processes are stable, capable, and optimised to deliver quality, safety, and productivity targets. Working closely with Process Technicians & the Production, Maintenance, Toolroom and Quality departments. The Process Engineer provides advanced technical support, root cause analysis, and methodical process optimisation using recognised die casting methodologies.
Act as the highest level of on-shift technical decision maker for all HPDC processes. Provide direction to Process Technicians on process adjustments, die changes, and fault diagnosis. Lead start-ups, restarts, die trials, parameter validation, and approval of first-off samples. Set up and be involved in all automation processes for Die cast Cells. (6 axis robots, Conveyor systems) Ensure that all process changes are controlled, logged, and aligned with engineering standards. Make safe, effective decisions under time pressure to maintain production and minimise downtime. Work closely with the Process Supervisor and Manager on company objectives.
Essential: Strong background in high-pressure die casting (HPDC), ideally in automotive-grade environments. Proven experience analysing shot profiles, thermal behaviour, and casting defects. Ability to lead technical decision-making and guide teams under pressure. Strong understanding of gating, venting, vacuum systems, die cooling, and metal flow dynamics. Proven problem-solving ability using structured methods and data-driven decision making. Competent with shot monitoring software, SPC analysis, and process documentation.
Desirable: Degree or HNC/HND in Mechanical, Manufacturing, Metallurgy, or related engineering field. Experience with aluminium alloys. Familiarity with DOE methods, Six Sigma, and statistical tools. Strong understanding of hydraulic systems, accumulators, and servo-controlled shot systems. Experience in continuous improvement programs (Kaizen, Lean). KUKA and ABB 6 axis robot knowledge / experience.
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