Additive Manufacturing Design Engineer

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ADDITIVE MANUFACTURING DESIGN ENGINEER

About the Role:
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.

Key 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)

Qualifications & Requirements:

• Languages: Spanish — Native | English — Intermediate (written and spoken).
• Education: Bachelor's degree in Mechanical, Metallurgical, Materials Engineering or (or related field).
• Experience: Minimum 2 years in a foundry process roles, fusion, foundry engineering preferred.
• ​​​​​​​Gating & Risering Design
• Metallurgy & Casting Processes
• CAD Modeling (3D)
• Casting Simulation Software
• Foundry Process Knowledge
• Binder Jet / Sand AM Printing
• 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

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