Manufacturing Engineer - Lost Foam

Are you ready for what’s next?  

Come explore opportunities within Brunswick, a global marine leader committed to challenging conventions and innovating next-generation technologies that transform experiences on the water and beyond.  Brunswick believes “Next Never Rests™,” and we offer a variety of exciting careers and growth opportunities within united teams defining the future of marine recreation. 

Location: Fond du Lac, WI – Plant 17

Workplace Category: Onsite

Travel Required: No

Direct Reports: 0

Pay Range: $62,800 - $90,500

Visa Sponsorship: Applicants must be currently authorized to work in the United States.  This position is not eligible for employment visa sponsorship now or in the future. 

Relocation: This position is not eligible for relocation assistance.

Innovation is the heart of Brunswick.  See how your contributions will help transform vision into reality:

Position Overview: 

As a Manufacturing Engineer - Lost Foam, you will play a hands-on, high-impact role in Mercury's aluminum lost foam foundry (Plant 17), developing technical ownership for a defined family of castings from foam pattern production through finished cast parts. This role is ideal for an engineer who wants to work directly on the shop floor, apply engineering fundamentals in a real manufacturing environment, and see process improvements translate into safe, stable production and castings that exceed customer expectations.

You will partner closely with operators, foam molding, tooling, quality, maintenance, controls, machining, finishing, and other cross-functional teams to improve processes, solve production challenges, and strengthen performance across the entire lost foam value stream.

At Brunswick, we have passion for our work and a distinct ability to deliver.

Essential Functions:  

• Provide hands-on technical engineering support and subject matter expertise for a defined family of lost foam castings across the entire manufacturing process
• Monitor, collect, and analyze operating data to understand the effects of key process parameters and identify improvement opportunities
• Provide day-to-day production support by troubleshooting casting defects, process variation, and upstream or downstream conditions
• Lead and support continuous improvement initiatives focused on defect reduction, process stability, productivity, cost reduction, ergonomics, and safety
• Apply a systems approach to problem solving by evaluating how foam molding, cluster preparation, coating, sand, compaction, pouring, extraction, finishing, machining, leak testing, painting, and other operations influence final part quality
• Collaborate with operations, quality, maintenance, controls engineering, tooling, and project management teams to implement process improvements
• Support new casting program launches by providing DFM input and participating in tooling, simulation, process development, validation, and part review activities
• Read and interpret casting and machining drawings, tolerances, specifications, CMM reports, inspection results, and other technical requirements
• Serve as a contributor to the PPAP process, supporting process documentation, validation, capability studies, and customer requirements

Diversity of thought and experiences is fundamental when imagining the unimaginable. Certain skillsets/experiences are necessary; however, others can be developed along the way.

Required Qualifications:  

• Bachelor’s degree in Manufacturing, Mechanical, Industrial, or Metallurgical Engineering or equivalent
• 0 to 5 years manufacturing, engineering, foundry, or related experience
• Provide hands-on technical engineering support and subject matter expertise for a defined family of lost foam castings across the entire manufacturing process.
• Monitor, collect, and analyze operating data to understand the effects of key process parameters and identify improvement opportunities.
• Provide day-to-day production support by troubleshooting casting defects, process variation, and upstream or downstream conditions.
• Lead and support continuous improvement initiatives focused on defect reduction, process stability, productivity, cost reduction, ergonomics, and safety.
• Apply a systems approach to problem solving by evaluating how foam molding, cluster preparation, coating, sand, compaction, pouring, extraction, finishing, machining, leak testing, painting, and other operations influence final part quality.
• Collaborate with operations, quality, maintenance, controls engineering, tooling, and project management teams to implement process improvements.
• Support new casting program launches by providing DFM input and participating in tooling, simulation, process development, validation, and part review activities.
• Read and interpret casting and machining drawings, tolerances, specifications, CMM reports, inspection results, and other technical requirements.
• Serve as a contributor to the PPAP process, supporting process documentation, validation, capability studies, and customer requirements.
• Demonstrated communication and interpersonal skill with the ability to work effectively with cross-function teams

• Proficiency with Microsoft 365, including Excel, Teams, SharePoint, and Planner

Preferred Qualifications: 

• Completed coursework related to metal casting, lost foam, sand molding, foundry processes, or manufacturing engineering

• Experience with PLCs, industrial controls, Allen-Bradley systems, ABB robotics, Ignition, SQL, Power BI, process traceability, shop-floor dashboards, data collection systems, or advance inspection technologies
• Experience with 3D CAD software and the ability to review part, pattern, tooling, and manufacturing designs
• Familiarity with Lean Manufacturing Six Sigma, statistical process control, or structured problem-solving methods
• Strong analytical and problem solving skills with the ability to use data and sound engineering judgement to make decisions
• Ability to deliver results independently and as part of a cross-functional team
• Demonstrated project management skills with the ability to manage multiple priorities
• Team-oriented mindset with the ability to learn quickly and thrive in a foundry environment
• Ability to work in a fast-paced, constantly evolving manufacturing environment with limited oversight
• Willingness to evaluate and implement new processes, systems, and technologies

Working Conditions:

• This position works in a Foundry environment

The hiring range for this position is $62,800 – $90,500 annually. The actual base pay offered will vary based on multiple factors including job-related knowledge/skills, relevant experience, business needs, and geographic location. Compensation decisions are dependent upon the specifics of the candidate’s qualifications and the business context. 

In addition to base pay, this position is eligible for an annual discretionary bonus.  This position is eligible to participate in Brunswick's comprehensive and high-quality benefits offerings, including medical, dental, vision, paid vacation, 401k (up to 4% match), Health Savings Account (with company contribution), well-being program, product purchase discounts and much more. Details about our benefits can be found here. 

Why Brunswick: 

Whatever tomorrow brings, we’ll be at the leading edge.  As the clear leader in the marine industry, we’re committed to our values and supporting our exceptional people. We offer and encourage growth opportunities within and across our many brands. In addition, we’re proud of being recognized for making a splash with numerous awards! 

About Mercury Marine

Mercury Marine is a world leading manufacturer of marine propulsion systems. A $2.6 billion division of Brunswick Corporation (NYSE: BC), Mercury designs, manufactures and distributes engines, services and parts for recreational, commercial and government marine applications, empowering boaters with products that are easy to use, extremely reliable and backed by the most dedicated customer support in the world with 10,000 service points globally. Mercury’s industry-leading brand portfolio includes Mercury outboard engines; Mercury MerCruiser sterndrive and inboard packages; Mercury global parts and accessories; Land ’N’ Sea, BLA, Payne’s Marine, Kellogg Marine & Lankhorst Taselaar marine parts distribution; and Mercury and Quicksilver parts and oils. More information is available at mercurymarine.com. 

Next is Now!  

We value growth and development, recognizing that people come with a wealth of experience and talent beyond just the technical requirements of a job. If your experience is close to what you see listed here, please still consider applying.

Brunswick is an Equal Opportunity Employer and considers all qualified applicants for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, protected veteran status or any other characteristic protected by federal, state, or local law.  Diversity of experience and skills combined with passion is key to innovation and inspiration and we encourage individuals from all backgrounds to apply.  If you require accommodation during the application or interview process, please contact [email protected] for support. 

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Brunswick does not accept applications, inquiries or solicitations from unapproved staffing agencies or vendors. For help, please contact our support team at: [email protected] or 866-278-6942.

All job offers will come to you via the candidate portal you create when applying through a posted position through https:///www.brunswick.com/careers.  If you are ever unsure about what is being required of you during the application process or its source, please contact HR Shared Services at 866-278-6942 or [email protected].

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