Senior Design Engineer Jobs in Beloit, WI (NOW HIRING)

We’re seeking a Senior Casting Engineer to support our Electric Systems Power Generation department. In this role, you'll be supporting the design and manufacturing of castings used to produce products like Integrated Drive Generators, Variable Frequency Generators, motors, and ram air turbines. 

As a Senior Casting Engineer, you’ll collaborate closely with design engineers, manufacturing engineers, and suppliers to ensure our mechanical and electromagnetic equipment meet rigorous cost, weight, and reliability standards.  You will develop and drive innovative solutions that are necessary to support our supplier and plant sites as we produce and deliver the industry leading products that power the aerospace industry. 

What You Will Do 

• Support Aerospace Component Production: Oversee the manufacturability of various components with a focus on housings and other components that are produced via complex geometry sand casting practices. 

• Engineering Drawing Review: Conduct thorough evaluations of engineering drawings to ensure designs are both feasible and optimized for manufacturability. 

• Casting Tooling Design and Evaluation: Design and review tooling for producing casted components, focusing on producibility, quality, and cost. 

• Manufacturing Process Development and Optimization: Collaborate with plant sites and suppliers to develop and refine manufacturing processes, troubleshoot issues, and drive continuous improvement. 

• Standard Work Development: Create and implement standardized work procedures to ensure consistency, quality, and efficiency in production processes. 

• Cost Reduction Initiatives: Work closely with plant sites and suppliers to analyze and reduce standard costs, implementing cost-saving measures without compromising quality. 

• Production Support and Problem Resolution: Identify root causes of production issues and implement corrective actions to maintain smooth and efficient operations. 

• Travel 25-50% 

What You Will Learn 

• You will learn how to lead the production of cutting-edge aerospace components, including Integrated Drive Generators and Variable Frequency Generators, making a tangible difference in advanced aerospace systems. 

• You will gain hands-on experience with complex electromagnetic systems, mastering skills from design and manufacturability to tooling and production optimization. 

Qualifications You Must Have  

• Typically requires a degree in Science, Technology, Engineering or Mathematics (STEM) and minimum 5 years prior relevant experience or an Advanced Degree in a related field and minimum 3 years of experience  

Qualifications We Prefer 

• Experience designing, producing, or supporting complex-geometry sand-cast components, particularly for aerospace or similar high-tech industries. 

• Proficiency in designing and evaluating tooling for cast components, including patterns, cores, gating, and casting simulation. 

• Experience in developing, optimizing, and troubleshooting manufacturing processes, with a track record of collaboration with plant sites and suppliers. 

• Experience with other processes that may be used in lieu of casting such as, traditional machining hogouts and additive manufacturing via powder bed fusion, material jetting, directed energy deposition, etc.  

• Proven ability to analyze and reduce standard costs while maintaining high quality, with experience in cost management and efficiency improvements. 

• Skilled in identifying root causes of production issues and implementing effective corrective actions to ensure smooth and efficient operations. 

• Ability to review and interpret engineering drawings to ensure designs are feasible and optimized for manufacturability. 

• Excellent interpersonal skills with a demonstrated ability to work effectively within multidisciplinary teams and establish strong working relationships. 

What We Offer 

Some of our competitive benefits package includes:    

• Medical, dental, and vision insurance   

• Three weeks of vacation for newly hired employees   

• Generous 401(k) plan that includes employer matching funds and separate employer retirement contribution, including a Lifetime Income Strategy option   

• Tuition reimbursement program  

• Student Loan Repayment Program   

• Life insurance and disability coverage   

• Optional coverages you can buy: pet insurance, home and auto insurance, additional life and accident insurance, critical illness insurance, group legal, ID theft protection  

• Birth, adoption, parental leave benefits  

• Ovia Health, fertility, and family planning   

• Adoption Assistance            

• Autism Benefit   

• Employee Assistance Plan, including up to 10 free counseling sessions   

• Healthy You Incentives, wellness rewards program  

• Doctor on Demand, virtual doctor visits   

• Bright Horizons, child and elder care services  

• Teladoc Medical Experts, second opinion program   

• And more!   

Learn More & Apply Now! 

We make modern flight possible for millions of travelers and our military every second.  Our major product lines are on-board virtually every aircraft flying. Be it keeping passengers safe with our emergency power generation systems or creating a positive in-flight experience through reliable cabin pressure controls and quieter engines, Power & Controls focuses on delivering a best-in-class experience to our customers. We hire the top people in the industry. Their ideas drive our performance, and their integrity keeps our customers happy. Join us as we take flight!  

*Please ensure the role type (defined below) is appropriate for your needs before applying to this role.