Pattern & Method Development Manager - Steel Casting Foundry

Job Summary

We are looking for an experienced Patterns & Methods Manager to lead our Pattern and Methoding Department. The ideal candidate will be responsible for managing the entire pattern and method development process for new and existing castings, ensuring optimum yield, quality, and process efficiency.

The candidate should have strong technical expertise in foundry practices, pattern equipment design, and method optimization for both Co2 and no-bake molding processes.

Roles & Responsibilities

• Lead and manage the pattern and method design team to develop efficient and cost-effective casting methods.
• Strong knowledge of foundry processes, pattern design, and method development.
• Review customer drawings, specifications, and requirements to prepare feasible and accurate casting methods.
• Plan and supervise pattern design, modification, and maintenance activities.
• Coordinate with the design, melting, molding, and machining teams for seamless production flow.
• Ensure optimum metal yield, solidification, and defect-free castings through proper methoding techniques.
• Approve gating and risering designs, chills, and other process-related parameters.
• Evaluate and approve new pattern layouts and tool designs for new product development.
• Lead process improvement projects focused on reducing rework, rejections, and pattern-related issues.
• Maintain proper records for pattern inventory, revisions, and method approvals.
• Collaborate with customers and design engineers for feasibility and process feedback.
• Provide training, guidance, and technical leadership to the pattern and methods team.

Key Skills & Expertise:

• Expertise in gating and risering systems, solidification principles, and defect analysis.
• Proficiency in CAD/3D modelling and simulation software (Magma soft, ProCAST, or equivalent preferred).
• Experience in handling no-bake, Co2 processes.
• Excellent leadership and communication skills with the ability to manage multi-skilled teams.
• Analytical and process-driven mind-set with a focus on productivity and quality improvement.

Preferred Candidate Profile:

• 15–25 years of relevant experience in pattern and method departments within a steel or ferrous foundry.
• Proven track record in new product development, method standardization, and pattern management.
• Strong technical understanding of casting simulation and foundry tooling.
• Ability to lead, train, and motivate a team of pattern makers, method engineers, and design staff.