Die Cast Engineer

The Die Cast Engineer will lead in the design, development, and optimization of aluminum die casting tooling and manufacturing processes. This role works closely with engineering, manufacturing, quality, and customers to ensure robust tooling designs that support high-quality, cost-effective production.

Responsibilities

• Design, calculate, and optimize aluminum die casting tooling, including mold sets, trimming dies, spray heads, and auxiliary tooling.
• Develop complete die casting tooling layouts, including gating systems, runners, overflows, venting, and cooling/heating channels.
• Perform tooling calculations and engineering analyses to improve tool life, casting quality, and manufacturing efficiency.
• Conduct Design for Manufacturing (DFM) reviews and utilize simulation results to optimize die designs and manufacturing processes.
• Support New Product Introduction (NPI) activities by collaborating with customers and cross-functional teams to ensure successful product launches.
• Oversee APQP activities at the plant level, including development and maintenance of Process Flow Diagrams, PFMEAs, and Control Plans.
• Support quoting activities by evaluating tooling concepts, manufacturing feasibility, cycle times, and costs.
• Analyze tooling and product Finite Element Analysis (FEA) and simulation data to recommend design improvements.
• Collaborate with production, quality, maintenance, and tooling teams to troubleshoot casting and tooling issues.
• Ensure compliance with customer specifications, engineering standards, and automotive quality requirements.
• Manage multiple engineering projects simultaneously while meeting established timelines and budgets.
• Support continuous improvement initiatives focused on quality, productivity, cost reduction, and process optimization

Qualifications

• Bachelor's degree in Mechanical Engineering, Metallurgical Engineering, or a related engineering discipline.
• Proven experience in aluminum die casting tooling design and process development.
• Strong knowledge of die casting tooling, process development, product launches, and manufacturing best practices.
• Proficiency in reading and interpreting 2D engineering drawings, 3D CAD models, GD&T, and manufacturing specifications.
• Experience using casting simulation software such as MAGMA, FLOW-3D, or similar.