Vacuum Melt Operator

Job Description

SeaCast, Inc. is seeking an experienced, safety-focused, and highly motivated Senior Vacuum Melt Operator / Supervisor to lead and optimize our precision investment casting operations. This role combines hands-on vacuum melt and casting responsibilities with technical leadership in metallurgy, process control, equipment reliability, employee development, and continuous improvement.

The ideal candidate brings a strong background in foundry operations, vacuum melting, and metallurgical processes, along with a passion for quality, safety, operational excellence, and team development. This is an excellent opportunity to play a key role in producing high-performance castings for demanding aerospace, defense, marine, and industrial applications.

Position Summary

The Senior Vacuum Melt Operator / Supervisor is responsible for safely operating vacuum and air casting systems while ensuring compliance with all process controls, quality requirements, standard operating procedures, and customer specifications. This position partners closely with Operations, Engineering, Quality, and Production teams to improve casting performance, reduce costs, maximize productivity, and develop a highly skilled workforce.

What You'll Do

Metallurgical Engineering & Process Control

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• Develop, maintain, and improve alloy specifications, melt procedures, and metallurgical process controls.
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• Monitor chemical composition, microstructure, and mechanical properties of cast materials.
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• Investigate metallurgical and casting defects utilizing root cause analysis techniques and corrective actions.
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• Support heat treat development, validation, and process optimization.
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• Ensure compliance with customer, industry, regulatory, and internal quality requirements.
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• Maintain process documentation, work instructions, SOPs, and technique cards.
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• Utilize SPC, statistical analysis, and continuous improvement tools to enhance process capability and quality.
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Vacuum Melt & Casting Operations

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• Create and execute furnace plans supporting production schedules.
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• Review casting schedules and coordinate operational requirements with supervisors and shift leads.
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• Operate vacuum and air casting furnaces, induction melting systems, hydraulic systems, cranes, hoists, and associated equipment.
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• Melt and pour ferrous, stainless steel, non-ferrous, and specialty alloys according to approved procedures.
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• Verify alloy chemistry, shell identification, charge weights, and production requirements before pouring.
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• Monitor and control critical melt and casting parameters throughout the process.
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• Maintain accurate process records and production documentation.
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• Safely transfer hot molds between burnout and casting operations.
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• Troubleshoot melt and casting issues to improve quality, yield, and productivity.
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Equipment Reliability & Maintenance

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• Perform preventive maintenance, cleaning, calibrations, and minor repairs on furnaces and support equipment.
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• Change furnace components including pots, leads, furnace oil, and related systems.
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• Monitor vacuum systems, hydraulic systems, power supplies, and process controls.
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• Troubleshoot equipment issues and support maintenance activities.
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• Maintain accurate maintenance records and equipment performance logs.
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• Participate in equipment audits, process trials, and reliability improvement initiatives.
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Leadership & Employee Development

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• Train, mentor, and certify employees in casting methods, foundry operations, and metallurgical best practices.
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• Support employee progression through SeaCast's Job Progression Records (JPR) program.
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• Provide technical leadership and day-to-day guidance to foundry personnel.
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• Foster teamwork, accountability, safety, and operational excellence.
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• Lead or support Lean Manufacturing and continuous improvement initiatives.
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• Assist with new product introductions, process validations, and customer requirements.
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• Participate in customer audits, technical reviews, and cross-functional problem-solving efforts.
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Qualifications

Required

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• Minimum 5 years of experience in precision investment casting, foundry operations, vacuum melt, or melt deck operations.
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• Strong understanding of metallurgy, alloy behavior, melting practices, and casting processes.
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• Experience operating induction melting furnaces, vacuum casting systems, and related foundry equipment.
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• Knowledge of ceramic shell systems, burnout processes, and investment casting methodologies.
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• Experience performing casting defect analysis and root cause investigations.
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• Ability to read and interpret engineering drawings, specifications, and technical documentation.
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• Strong troubleshooting, communication, leadership, and organizational skills.
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• Experience utilizing manufacturing data collection systems and computer-based process controls.
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Preferred

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• Aerospace investment casting experience.
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• Degree or coursework in Metallurgical Engineering, Materials Science, or related technical discipline.
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• Experience supporting aerospace, defense, marine, or other highly engineered cast products.
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• Lean Manufacturing, Six Sigma, ASQ, or related certifications.
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• Experience with casting simulation software such as MAGMASoft, ProCAST, or similar systems.
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• CAD software experience, including SolidWorks or related platforms.
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• Familiarity with AS9100, NADCAP, and other aerospace quality systems.
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• Forklift, crane, rigging, or hazardous material certifications.
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What Success Looks Like

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• Safe and efficient operation of all vacuum and air melt processes.
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• Consistent production of high-quality castings meeting customer requirements.
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• Continuous improvement in yield, throughput, process capability, and cost efficiency.
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• Development of a highly skilled and cross-trained workforce.
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• Strong collaboration across Operations, Quality, Engineering, and Production teams.
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Why SeaCast?

At SeaCast, you'll have the opportunity to contribute to complex, high-performance casting solutions while working alongside a team dedicated to craftsmanship, innovation, and continuous improvement. We are committed to developing our employees, advancing technology, and maintaining a culture built on safety, accountability, and excellence.

If you are a hands-on foundry professional with strong metallurgical expertise and leadership experience, we encourage you to apply and help drive the future of precision investment casting at SeaCast.