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Fabri

Senior Foundry Engineer

Boston, MA, United States
Billerica, MA, United States

$115,000 to $140,000 USD / year

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Job details

Pay: $115,000 to $140,000 USD / year
Experience: 5+ years of experience running foundry casting processes for aerospace, space, or other high-consequence hardware.
Posting language: English

Original job description

Senior Foundry Engineer Fabri is seeking a Senior Foundry Engineer to build and own the process development of high-performance superalloy castings for demanding aerospace and space-industry applications. This role is for someone who has operated inside a high-tempo, high-accountability foundry environment and wants direct ownership over how critical hardware is melted, cast, solidified, inspected, and iterated on, using first-principles physics rather than legacy playbooks. You will drive the development of Fabri’s high-temperature casting capability, starting with equiaxed superalloy castings and expanding toward more advanced solidification approaches over time. The emphasis is on process execution, defect elimination, and repeatable quality suitable for flight-critical hardware. The Company We are an early-stage investment casting startup building a fully integrated digital foundry. Our mission is to deliver precision metal castings with unparalleled speed and cost-effectiveness. By leveraging our exclusive high-throughput additive manufacturing process and AI-driven design software, we can deliver castings in days, saving our customers critical time and money. We are well capitalized and backed by top-tier investors and major customers, with significant funding raised in the past year. We’ve shipped our first customer parts and have generated significant commercial excitement in both the aerospace and industrial sectors. Fabri is located in Boston Metrowest. During this startup phase and for the foreseeable future, all employees will be on-site and closely involved with building and operating the end-to-end process. Fabri is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. We foster an environment where safety and commitment to quality are central in everything we do. The Role As Senior Foundry Engineer, you will develop Fabri’s high-temperature alloy casting processes, responsible for driving parts from melt to accepted hardware with speed, control, and quality. You will conduct root-cause failure analysis, eliminate casting defects, tighten process windows, and establish robust, repeatable manufacturing processes suitable for aerospace qualification.

You will work closely with mechanical design and other process leads on build/buy decisions to select, and commission next-gen foundry equipment that enables precise thermal and process controls to achieve high yields in an automated process for some of the most difficult to cast aerospace superalloys. Reporting directly to the CTO, you will operate with high ownership and direct influence over Fabri’s technical and manufacturing direction.

Responsibilities

Own process development and production readiness for aerospace superalloy castings (e.g., Ni-, Co-, and Ti-base systems), with a focus on repeatability, yield, and defect reduction.
Develop and mature equiaxed casting processes as the initial foundation of Fabri’s high-temperature capability, while applying experience from directionally solidified (DS) and/or single-crystal (SCX) systems to produce the highest quality castings, and enable future process expansion.
Design and control solidification behavior to manage grain structure, segregation, phase evolution, shrinkage, hot tearing, porosity, surface condition, and dimensional stability using a combination of SPC, DOE methods, and physics-based reasoning.
Work closely with the software team to develop thermal and solidification simulations to guide gating, risering, mold design, and thermal control decisions.
Work across the full foundry stack as needed, including patterns, shell systems, melt practice, pouring, and post-cast processing, ensuring strong linkage between process inputs and measured outcomes.
Partner with equipment, mechanical design, and automation engineers to define requirements and build custom foundry hardware that enables new casting and solidification approaches.
Interface directly with customers and internal stakeholders on technically deep discussions around material selection, casting strategy, qualification approach, and production readiness.
Rapidly transition processes from development into stable production ownership, moving programs forward at a pace consistent with modern aerospace and spaceflight development.

Qualifications

Even if you don’t meet every qualification, we encourage you to apply for this role. We value curiosity, problem-solving skills, and strong fundamentals.

Bachelor’s, Master’s, or PhD in Materials Science, Metallurgical Engineering, Mechanical Engineering, Aerospace Engineering, or a closely related field.
5+ years of experience running foundry casting processes for aerospace, space, or other high-consequence hardware.
Strong first-principles understanding of casting-relevant physics, including heat transfer, fluid flow, solidification, phase transformations, grain structure control, and surface phenomena.
Understanding of Statistical Process Control (SPC) and Design of Experiments (DOE) methods in improving and maintaining high quality casting processes
Demonstrated experience identifying casting defects, performing root-cause analysis, and driving process changes to eliminate them.
Hands-on experience working directly on the foundry floor, operating equipment and executing process steps alongside technicians and engineers.
Ability to operate effectively in a startup environment with high ownership, ambiguity, and a bias toward execution.
Ability to rapidly identify, learn, and reason across diverse, multi-disciplinary physics domains and process steps using a systems-engineering mindset, applying strong theoretical fundamentals to solve complex problems efficiently.

Fabri does not provide visa sponsorship for this position. To comply with ITAR regulations, candidates for this role must be US nationals (i.e., US citizens or lawful permanent residents) to be considered. Preferred Skills

Direct experience with superalloy investment casting for aerospace or space applications.
Exposure to directionally solidified and/or single-crystal casting processes.
Experience spanning multiple foundry functions, including patterns, shelling, casting, and post-processing.
Experience using thermal, fluid, or solidification simulation tools to inform process decisions.
Experience working in an AS9100-compliant environment.
Prior work in a startup or rapid-iteration manufacturing environment.
Experience in a startup with high ownership and ambiguity.

What We Offer

High ownership in solving some of the hardest problems in advanced manufacturing and industrial automation of the US’ most critical supply chains
Freedom from legacy foundry constraints – ownership and authority to question entrenched practices, pursue bold ideas, and rapidly innovate without barriers
Direct influence over equipment selection, process architecture, and long-term foundry strategy.
A small, elite, hands-on engineering team with deep technical autonomy.
Competitive compensation, meaningful equity, and the chance to work on hardware that advances humanity’s future.

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