Additive Manufacturing Design Engineer

Job Purpose

Responsible for the end-to-end design of sand molds and cores, including feeding and gating systems, for centrifugal pump castings produced on our ExOne S-Max binder jet printer. You will run solidification simulations, collaborate with internal foundry teams and external partners, and continuously improve casting yield and quality.

Job Responsibilities

• Review the engineering dispatch list to prioritize and complete job orders within the quoted time frame.
• Design 3D sand molds and cores for binder jet additive manufacturing using the ExOne S-Max platform.
• Generate detailed design sheets for each mold and core package to facilitate metal pouring and assembly at any foundry.
• Calculate and design feeding and gating systems prior to casting simulation and 3D printing.
• Perform casting solidification simulations on all mold packages to guarantee castability and minimize defects.
• Collect critical process feedback from foundry partners to improve casting yield and refine simulation parameters, reducing NCMRs and scrap.
• Optimize mold and core designs to maximize utilization of the printer job box volume, reducing print costs.
• Follow up on internal and external NCMRs; implement engineering design changes to 3D models to ensure product quality.
• Support the Process Engineer with print job preparation, machine start-up, and routine maintenance.
• Support the Process Engineer in reviewing laboratory test bar results to improve existing machine recipes.
• Research and expand the supplier base for raw materials (silica sand, resins, activators, cleaners, and related additives).

Requirements:

• Bachelor's degree in Mechanical, Metallurgical, Materials Engineering or (or related field) 
• Minimum 2 years in a foundry process roles, fusion, foundry engineering preferred.
• Spanish—Native
• English—Intermediate (written and spoken)
• Strong analytical thinking and structured problem-solving
• Excellent communication skills, able to convey technical details clearly to foundry and engineering teams
• Highly organized with effective time management and ability to handle multiple concurrent job orders
• Team-oriented with a collaborative work style; comfortable interfacing cross-functionally
• Results-driven mindset with a focus on continuous improvement

Experience