Senior Casting Process Engineer - Own Solidification and Process Development for Flight-Critical Metal Castings Billerica, MA | On-site Join a venture-backed foundry startup that is rethinking investment casting from first principles. The company combines additively manufactured patterns, in-house process software, and custom equipment to produce high-performance castings for aerospace, space, and defense hardware on timelines legacy suppliers cannot match. Reporting directly to the CTO, you will lead development of the high-temperature casting capability, starting with equiaxed nickel superalloy parts and growing toward more advanced solidification methods. You will connect thermal history to real metallurgical outcomes, drive parts from melt to accepted hardware, and help design the foundry equipment itself rather than inheriting someone else's process. We are an early-stage, well-capitalized advanced manufacturing startup rebuilding domestic metal casting capacity for aerospace, defense, and energy customers. Backed by leading venture firms and strategic aerospace and defense investors, the company has a production foundry up and running, is shipping parts to customers, and plans to bring additional foundries online as demand grows. The founding team comes from top commercial space and metal additive manufacturing companies, and every employee works on-site, close to the physical process.
Job Duties:- Own process development and production readiness for high-temperature alloy castings, with a focus on yield, repeatability, and defect reduction
- Relate thermal gradient and growth rate to grain structure, segregation, and microstructure, and use that understanding to control outcomes
- Predict, measure, and control feeding and shrinkage through the mushy zone to eliminate shrinkage porosity, microporosity, and hot tearing
- Tighten process windows using SPC, DOE, and physics-based reasoning, and lead root-cause analysis on casting defects
- Partner with the software team to build in-house thermal and solidification models that guide gating, risering, mold design, and thermal control
- Work across the full process as needed, including patterns, shell systems, melt practice, pouring, and post-cast processing
- Define requirements for and help commission custom foundry equipment that delivers precise thermal and process control
- Lead technical discussions with customers on material selection, casting approach, qualification strategy, and production readiness
- Transition processes quickly from development into stable production at a pace that matches modern aerospace programs
Qualifications:
Bachelor's, Master's, or PhD in Materials Science, Metallurgical Engineering, Mechanical Engineering, Aerospace Engineering, Physics, or a related field 5+ years developing or running a high-temperature process where solidification, melting, or microstructure drives results, such as casting, metal additive manufacturing, welding, crystal growth, or thermal processing Strong grasp of solidification fundamentals, including nucleation and growth, constitutional supercooling, columnar-to-equiaxed transition, G/R relationships, segregation, and shrinkage Solid grounding in heat transfer, fluid flow, thermodynamics, and phase transformations Working knowledge of SPC and DOE for improving and sustaining process quality Demonstrated record of identifying defects, running root-cause investigations, and implementing corrective process changes Comfortable working hands-on with equipment and close to the process, not only at a deskU.S. person status (U.S. citizen or lawful permanent resident) required under ITARPreferred Experience Nickel superalloy or other high-temperature investment casting for aerospace or space applications Familiarity with directional solidification or single-crystal processes Hands-on foundry floor experience alongside technicians and engineers Experience spanning patterns, shelling, casting, and post-processing Solidification or flow simulation tools such as ProCAST, MAGMASOFT, Flow-3D, or equivalent Designing, building, or commissioning process equipment Work in an AS9100 quality environment Startup or rapid-iteration manufacturing experience
Why Join Us:- Rebuild foundry process and equipment from the ground up without legacy constraints
- Direct influence over equipment selection, process architecture, and long-term foundry strategy
- Report directly to the CTO with real technical autonomy
- Work on flight-critical hardware that matters to national security and aerospace
- Early-employee equity with real upside as the company expands from one foundry to many
- Fast career growth: early hires are expected to step into technical leadership as the team scales
- Small, hands-on team with no bureaucracy, where decisions happen in days rather than quarters
- A mission that matters: rebuilding domestic production of castings used in aircraft engines, defense systems, and energy infrastructure
- Competitive base salary
- Medical, dental, and vision coverage 401(k) plan
- Unlimited PTO$145,000 - $180,000 + equity
This position requires access to technical data controlled under the International Traffic in Arms Regulations (ITAR). Applicants must be U.S. persons (U.S. citizens or lawful permanent residents). Visa sponsorship is not available.
