Senior Foundry Engineer
Confirmed on the employer's own hiring board on Oct 13, 2026. First seen by Alion on Oct 5, 2026.
About the Opportunity
Our client is building the future of American industrial power by developing fully automated investment casting foundries. In an era where demand for precision metal castings is skyrocketing but domestic supply chains are failing, our client is stepping in to restore critical manufacturing capabilities for the U.S. Aerospace and Defense sectors.
Backed by industry titans like RTX Group (Raytheon/Pratt & Whitney) and Lockheed Martin, our client is a well-capitalized startup already shipping parts and moving rapidly toward AS9100 certification. We are looking for a Senior Foundry Engineer to serve as the foundational expert on an elite team, owning the nickel superalloy casting process from the ground up.
The Role
Reporting directly to the CTO, you will be the first true foundry expert in the building. This isn't a desk job where you monitor spreadsheets; you will be the architect of a new production facility. You will bring the institutional knowledge necessary to turn artisanal casting into repeatable, high-tech engineering.
What You Will Be Doing:
Process Ownership: Lead the development of nickel superalloy investment casting processes-from melt practice and shell interaction to solidification and defect elimination.
Equipment Commissioning: Source and commission critical foundry equipment, including vacuum induction melters (VIM) and downstream inspection tooling.
Cross-Functional Collaboration: Partner with shell engineering and metallurgy teams, while working with software engineers to encode foundry "DNA" into a proprietary AI-driven Foundry OS.
Scale-Up & Design: Help the CEO and CTO design a next-generation 60,000 sq. ft. production facility, defining the workflow for the ideal automated foundry.
Quality & Compliance: Drive processes toward AS9100 certification for flight-critical hardware used by major defense primes.
Who You Are
Experienced: You have 5+ years of hands-on experience in an investment casting environment (e.g., PCC, Howmet, GE Aerospace, etc.).
Technical: You have "poured metal" and lived on the foundry floor. You understand the nuances of high-temperature alloys and what it takes to hit aerospace specifications.
Mission-Driven: You are energized by the prospect of reviving a critical industry and contributing to national security.
Builder Mentality: You thrive in a fast-moving startup environment where you have the autonomy to make decisions without legacy bureaucracy.