{"id":2064932,"url":"https://alion.io/job/maclean-power-systems-tool-design-engineer","title":"Tool Design Engineer","company":{"id":2440425,"name":"MacLean Power Systems","domain":"macleanpower.com","url":"https://alion.io/company/macleanpower","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Dayforce","truth_index":{"grade":"B","score":75,"open_postings":21,"ghost_share":0,"stale_share":1,"repost_share":0,"time_to_fill_p50_days":null,"computed_at":"2026-10-13T05:45:00Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"middle","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Alabaster, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":70000,"max_usd":129000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":3384},"experience_years_min":3,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-09-30T06:00:00Z","employer_posted_date":"2026-10-08","last_verified_at":"2026-10-13T09:40:40Z","board_verified":true,"closed_at":null,"days_open":13,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":13},"description":"Job Summary\nDesigns and develops foundry tooling for a sand casting operation, with a focus on patterns, pattern plates, and core boxes. This role uses MAGMA casting simulation to model mold filling and solidification, and designs new plates to replace legacy tooling that contributes to mold shift and poor yield. The engineer works with the Foundry, South Floor, Tool Room, and CNC teams to improve casting quality, yield, and throughput.\nJob Duties\nDesign and develop foundry tooling for sand casting, including patterns, match plates, cope and drag plates, core boxes, and related fixtures\nRun MAGMA casting process simulations of mold filling, solidification, and cooling to predict and prevent defects such as shrinkage, porosity, misruns, and cold shuts\nDesign and optimize gating, runner, riser, and feeding systems, and validate them through simulation and trial pours\nLead the redesign of legacy pattern plates that cause mold shift and poor yield, including planning and managing the changeover to new tooling\nCreate 3D models, drawings, and CNC-ready models, and work with CNC programmers and the Tool Room so tooling is machined accurately and efficiently\nApply pattern allowances (shrinkage, draft, machining stock), parting line placement, and GD&T to all tooling designs\nLead first-article and trial runs for new or modified tooling; analyze casting defects and make design corrections\nTrack scrap, yield, and mold shift results before and after tooling changes, and report on improvements\nMaintain tooling records, revision control, and pattern and plate documentation\nProvide design-for-casting input to NPD and Product Engineering on new parts\nCollaborate with team members to increase overall throughput\nComplete all necessary documents fully and accurately\nAdhere to 5S standards (e.g., maintain cleanliness of work area, etc.)\nFollow all Safety, Environmental and Quality policies and procedures\nPerform other duties as assigned\nExperience and Education\nBachelor's degree in Mechanical, Manufacturing, or Metallurgical Engineering, or equivalent experience\n3+ years of experience in tooling or pattern design for a sand casting foundry\nHands-on experience with MAGMA (MAGMASOFT) or similar casting simulation software\nProficiency in 3D CAD software (SolidWorks or similar) and creating production drawings\nWorking knowledge of CNC machining and design for manufacturability\nPerform work under minimal supervision and refer only the most complex issues to higher level staff\nCompetencies/ Skills\nAbility to set up, run, and interpret MAGMA casting simulations\nStrong knowledge of the sand casting process, including molding, coring, gating, risering, and shrinkage\n3D modeling, detailed drawing, and GD&T skills\nStrong problem-solving skills, including root cause analysis tools (5 Why, fishbone, 8D)\nAbility to analyze scrap and yield data, manage multiple tooling projects, and meet deadlines\nStrong verbal, written, and interpersonal communication skills","description_format":"text","description_chars":2978,"description_truncated":false,"requirements":{"experience_years_min":3,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":true},"security_clearance":false,"languages":[]},"benefits":[],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":["Energy & Utilities","Science & Engineering","Electrical & Electronic Engineering"],"lifecycle":[{"event":"open","at":"2026-10-08T03:27:31Z"}],"visa":[],"liveness":{"score":54,"band":"ok","label":"Likely open","p_open":1,"p_active":0.597,"p_room":0.9,"age_days":12,"expected_fill_days":24,"reasons":["conf:2","stale_co","velocity","win:mid"],"computed_at":"2026-10-13T05:45:00Z"},"pay":null,"html_url":"https://alion.io/job/maclean-power-systems-tool-design-engineer","json_url":"https://alion.io/job/maclean-power-systems-tool-design-engineer.json","meta":{"generated_at":"2026-10-13T12:07:15Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler_verified","counted_by":"address","units_charged":1,"used_today":18886,"day_limit":null,"remaining_today":null,"minute_limit":300,"resets_at":"2026-10-14T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":2440425},"rest":"https://alion.io/mcp/rest/get_company?id=2440425"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fmaclean-power-systems-tool-design-engineer"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fmaclean-power-systems-tool-design-engineer"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fmaclean-power-systems-tool-design-engineer"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/maclean-power-systems-tool-design-engineer\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fmaclean-power-systems-tool-design-engineer"}]}