Sand Casting Subject Matter Expert (SME)

Sand Casting Subject Matter Expert (SME)

Chicago, Illinois Onsite

Position Summary: We are seeking an experienced Sand Casting Subject Matter Expert (SME) with deep technical knowledge of metal casting processes used in the aerospace industry. This expert will serve as a key technical resource, working directly with our client's supply base to evaluate, develop, and strengthen casting suppliers, ensure compliance with aerospace requirements, and support production readiness. The ideal candidate brings extensive hands on foundry experience, strong supplier development skills, and the ability to guide suppliers toward robust, repeatable, and high quality casting processes.

Technical Expertise & Process Development

Provide expert guidance on sand casting processes, including pattern design, gating/risers, metallurgy, heat treatment, and NDT expectations for aerospace components.

Review and validate supplier process control plans, PFMEAs, work instructions, and overall manufacturing readiness.

Troubleshoot casting defects and drive corrective actions to improve yield and first pass quality.

Supplier Support & Development

Assess supplier capability, equipment robustness, and process maturity through on site evaluations or virtual technical reviews.

Assist suppliers in implementing best practices, process standardization, and quality improvements aligned with aerospace standards (e.g., AS9100, NADCAP for NDT or heat treat).

Partner with suppliers to improve lead time, throughput, and capacity planning.

Quality & Compliance

Ensure suppliers meet client requirements for dimensional accuracy, metallurgical integrity, and documentation traceability.

Support root cause investigations for casting nonconformances and help drive suppliers to sustainable, data driven corrective actions.

Collaborate with quality and engineering teams to ensure compliance with material specifications, special process requirements, and flight critical standards.

Cross Functional Collaboration

Act as a technical liaison between the client, suppliers, design engineering, and manufacturing engineering teams.

Provide clear communication on supplier status, risks, timelines, and recommended actions.

Support new product introduction (NPI) by evaluating manufacturability of new casting designs.

Qualifications:

Required

8+ years of experience in sand casting within aerospace, defense, or other high integrity industries.

Strong knowledge of ferrous and/or non ferrous aerospace alloys, gating/risering methodology, solidification principles, and defect analysis.

Direct experience working with or at foundries producing complex cast components.

Understanding of aerospace quality standards (AS9100, NADCAP processes, material certs, NDT methods).

Proven ability to work directly with suppliers to improve capability and performance.

Ability to travel to supplier locations as required.

Preferred

Experience with supplier development, APQP, PPAP, or similar structured quality processes.

Background in design for manufacturability (DFM) for castings.

Metallurgical engineering or materials science degree.