Engineer - Methoding & Simulation

Position: Methoding & Simulation Engineer

Experience: Min 5yrs & above

Industry: Foundry / Casting (Ferrous )

Reports To: Foundry Head

Role Overview

We are seeking a highly skilled Methoding & Simulation Engineer with strong experience in foundry methoding, casting simulation, and process optimization. The candidate will be responsible for designing gating and risering systems, preparing casting drawings with allowances, and performing casting simulation using advanced software tools to ensure defect-free, cost-effective castings.

Key Responsibilities

• Develop methoding layouts (gating & risering) for new and existing castings.
• Prepare 2D and 3D casting drawings/models by applying contraction, machining, and draft allowances for use in simulation software.
• Perform solidification and flow simulations using industry-standard software (e.g., MAGMASOFT, ProCAST, AutoCAST, or equivalent).
• Optimize casting design for yield improvement, quality enhancement, and cost reduction.
• Analyze simulation results to identify potential defects (shrinkage, porosity, inclusions, misruns, etc.) and propose corrective actions.
• Work closely with Pattern, production and other teams to finalize casting designs and ensure manufacturability.
• Support production trials, troubleshoot casting issues, and provide technical guidance on corrective actions.
• Maintain simulation database, prepare technical documentation, and standardize methoding practices.
• Ensure compliance with quality standards, customer specifications, and foundry best practices.
• Provide technical support in customer discussions, design reviews, and new product development (NPD) activities.

Preferred candidate profile

Required Skills & Competencies

• Strong knowledge of foundry processes (sand casting,)
• Hands-on experience with casting simulation software (MAGMASOFT, ProCAST, AutoCAST or equivalent)
• Proficiency in 2D CAD software (AutoCAD, or equivalent)
• Ability to apply casting allowances (contraction, machining, draft, distortion) in drawing preparation
• Deep understanding of metallurgy, solidification principles, and defect mechanisms
• Proficiency in 3D CAD tools (SolidWorks, CATIA, Pro e or equivalent)
• Ability to interpret customer drawings, QAP, and technical specifications
• Good communication and cross-functional collaboration skills

Experience & Qualifications

• B.E./B.Tech in Metallurgical, Mechanical, Production, or Foundry Engineering.
• 58 years of experience in reputed foundries with proven track record in methoding and casting simulation.
• Exposure to development of critical/complex castings for energy, or heavy engineering sectors preferred.
• Experience in defect analysis and root cause problem-solving.