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- Tasks: Lead process optimisation in high-pressure die casting and ensure quality and productivity.
- Company: Join CastAlum, a leading aluminium die casting company with a global reach.
- Benefits: Enjoy life insurance, on-site parking, and sick pay.
- Why this job: Make impactful decisions in a dynamic environment and enhance your engineering skills.
- Qualifications: Strong background in HPDC and problem-solving skills required.
- Other info: Opportunity for career growth in a supportive team atmosphere.
The predicted salary is between 36000 - 60000 £ per year.
Company Description
CastAlum is an internationally acclaimed aluminium die casting and machining centre located in Welshpool, UK. The site was a Greenfield development in the winter of 2000-2001, serving one customer only. 20 years on, the company supplies parts to the UK, Europe, Canada, and Mexico. We have grown from die casting aluminium parts only to supplying a range of products (using high pressure die casting, squeeze die casting, and machining). We can supply aluminium components as cast, cast & machined, or assembled & tested according to the needs of our customers.
Job Description
The Process Engineer is the on-shift technical authority responsible for leading all process-related decision making across the high-pressure die casting (HPDC) department. The role ensures casting processes are stable, capable, and optimised to deliver quality, safety, and productivity targets. Working closely with Process Technicians & the Production, Maintenance, Toolroom and Quality departments, the Process Engineer provides advanced technical support, root cause analysis, and methodical process optimisation using recognised die casting methodologies.
Key Responsibilities
- Act as the highest level of on-shift technical decision maker for all HPDC processes.
- Provide direction to Process Technicians on process adjustments, die changes, and fault diagnosis.
- Lead start-ups, restarts, die trials, parameter validation, and approval of first-off samples.
- Set up and be involved in all automation processes for Die cast Cells (6 axis robots, Conveyor systems).
- Ensure that all process changes are controlled, logged, and aligned with engineering standards.
- Make safe, effective decisions under time pressure to maintain production and minimise downtime.
- Work closely with the Process Supervisor and Manager on company objectives.
Qualifications, Skills & Experience
Essential:
- Strong background in high-pressure die casting (HPDC), ideally in automotive-grade environments.
- Proven experience analysing shot profiles, thermal behaviour, and casting defects.
- Ability to lead technical decision-making and guide teams under pressure.
- Strong understanding of gating, venting, vacuum systems, die cooling, and metal flow dynamics.
- Proven problem-solving ability using structured methods and data-driven decision making.
- Competent with shot monitoring software, SPC analysis, and process documentation.
Desirable:
- Degree or HNC/HND in Mechanical, Manufacturing, Metallurgy, or related engineering field.
- Experience with aluminium alloys.
- Familiarity with DOE methods, Six Sigma, and statistical tools.
- Strong understanding of hydraulic systems, accumulators, and servo-controlled shot systems.
- Experience in continuous improvement programs (Kaizen, Lean).
- KUKA and ABB 6 axis robot knowledge / experience.
Additional Information
- Life insurance
- On-site parking
- Sick pay
Process Engineer employer: CastAlum
Contact Detail:
CastAlum Recruiting Team
StudySmarter Expert Advice 🤫
We think this is how you could land Process Engineer
✨Tip Number 1
Network like a pro! Reach out to folks in the industry, especially those at CastAlum. A friendly chat can open doors and give you insights that a job description just can't.
✨Tip Number 2
Prepare for the interview by brushing up on your HPDC knowledge. Be ready to discuss your experience with die casting processes and how you've tackled challenges in the past. Show us you're the problem-solver we need!
✨Tip Number 3
Don’t forget to showcase your teamwork skills! As a Process Engineer, you'll be working closely with various departments. Share examples of how you've collaborated effectively in previous roles.
✨Tip Number 4
Apply through our website! It’s the best way to ensure your application gets noticed. Plus, it shows us you're genuinely interested in being part of the CastAlum team.
We think you need these skills to ace Process Engineer
Some tips for your application 🫡
Tailor Your CV: Make sure your CV is tailored to the Process Engineer role. Highlight your experience with high-pressure die casting and any relevant technical skills. We want to see how your background aligns with what we do at CastAlum!
Craft a Compelling Cover Letter: Your cover letter is your chance to shine! Use it to explain why you're passionate about the role and how you can contribute to our team. Be sure to mention specific experiences that relate to the job description.
Showcase Your Problem-Solving Skills: In your application, don’t forget to highlight your problem-solving abilities. Share examples of how you've tackled challenges in previous roles, especially those related to process optimisation and technical decision-making.
Apply Through Our Website: We encourage you to apply through our website for a smoother application process. It’s the best way for us to receive your application and ensures you’re considered for the role. We can’t wait to hear from you!
How to prepare for a job interview at CastAlum
✨Know Your Die Casting Inside Out
Make sure you brush up on your knowledge of high-pressure die casting processes, especially if you've worked in automotive-grade environments. Be ready to discuss specific techniques like gating, venting, and metal flow dynamics, as these will likely come up during the interview.
✨Showcase Your Problem-Solving Skills
Prepare examples of how you've tackled process-related challenges in the past. Use structured methods and data-driven decision-making to illustrate your approach. This will demonstrate your ability to lead technical decisions under pressure, which is crucial for the role.
✨Familiarise Yourself with Automation
Since the role involves setting up automation processes for die cast cells, it’s a good idea to have a solid understanding of 6-axis robots and conveyor systems. If you have experience with KUKA or ABB robots, be sure to highlight that during your interview.
✨Align with Company Objectives
Research CastAlum's goals and values before your interview. Be prepared to discuss how your skills and experiences align with their objectives, particularly in terms of quality, safety, and productivity targets. This shows that you're not just looking for a job, but are genuinely interested in contributing to their success.
