Principal Casting Engineer

About the role

LevelUP HCS is seeking a Principal Casting Engineer to act as the senior technical authority for casting equipment, tooling, processes and metallurgy in the production of aero‑engine components. The role will guide investment casting operations, develop specifications and qualification plans, and mentor the engineering team to ensure technical excellence.

Key responsibilities

• Lead all technical decisions on casting equipment, tooling, processes and metallurgy for aero‑engine components.
• Define and select equipment such as vacuum induction melting furnaces, DS/SX furnaces, shell rooms, wax injection systems, NDT and HIP facilities.
• Develop tooling strategies for wax dies, ceramic cores, shell systems, grain selectors and large structural castings.
• Provide expertise on alloy selection, gating and feeding design, solidification modelling and defect resolution.
• Create process specifications, qualification plans and technical training for the local team.
• Mentor junior engineers and serve as the go‑to expert on casting metallurgy.

Required profile

• 15+ years of hands‑on experience in investment casting of aero‑engine components.
• Deep knowledge of airfoil casting (equiaxed, DS, SX) and large structural castings.
• Strong background with nickel‑based superalloys such as CMSX‑4, René N5, MAR‑M247, IN738.
• Proven experience with shell systems, ceramic cores and grain control techniques.

Required skills

• Casting equipment
• MAR‑M247
• Shell systems
• Simulation tools
• Defect resolution
• Shell rooms
• Magmasoft
• CMSX‑4
• Nickel‑based superalloys
• Ceramic cores
• Grain control techniques
• NDT
• Solidification modelling
• Wax injection
• DS SX furnaces
• Metallurgy
• Gating and feeding design
• Heat treatment
• René N5
• HIP
• IN738
• Tooling strategies
• Alloy selection
• Investment casting
• Tooling processes
• ProCAST
• Vacuum induction melting furnaces