Casting Process Simulation & Yield Improvement Intern

Casting Process Simulation & Yield Improvement Intern (MAGMA/SolidWorks)

Wisconsin Aluminum Foundry | Manitowoc, WI | Paid, 12–14 weeks, May/June to August 2027 | Day Shift, 6 am - 2:30 pm

About Wisconsin Aluminum Foundry
Since 1909, Wisconsin Aluminum Foundry (WAF) has made aluminum, brass and bronze castings for customers with the toughest requirements: heavy-duty truck, automotive, marine, agriculture, defense and medical. Our Manitowoc foundry runs permanent mold, low pressure, green sand and air set processes, then heat treats, machines and finishes in-house. We're a three-time Wisconsin Manufacturer of the Year, and our people stay: average tenure is 20+ years.
Our interns don't shadow. They own a real project, work alongside engineers and operators on the floor, and present measurable results to leadership at the end of the summer.

Simulate it before we pour it. You'll use MAGMA and SolidWorks on real production castings to find where metal, time and money are being lost, then prove your fix on the floor.

What you'll do:

• Model solidification, filling and gating on target production jobs in MAGMA
• Redesign gating, risers and feeding in SolidWorks to improve yield and cut scrap
• Test your changes on the floor with process engineers and the foundry crew
• Track scrap, pour weight and finishing time before and after each change
• Find ways to reduce grinding, cut-off and other finishing time
• Present your results and recommendations to WAF leadership in August

What you'll deliver:

By the end of the summer, you'll report:

• Scrap dollars saved on your target jobs
• Annual pounds of aluminum saved, with the dollar value
• Finishing time reduced per part, where it applies

What you bring:

• Pursuing a degree in mechanical, materials, metallurgical or manufacturing engineering
• Understanding of solidification and gating principles
• SolidWorks or similar 3D CAD experience
• Problem-solving ability: you dig into root cause, not just symptoms
• Attention to detail with data and measurements
• Bonus: MAGMA, Flow-3D or other casting simulation experience, or foundry coursework

What you get:

• Paid, hands-on engineering work on parts that ship to real customers
• Industry-standard simulation software experience that stands out on a resume
• A results story with real numbers for your next interview
• Mentorship from WAF engineers

Make your simulation pour for real. Apply at wafco.com/careers and spend your summer turning MAGMA models into foundry improvements!