Sr. Tooling Engineer, Casting

Description:
Tesla is looking for a highly motivated Tooling Engineer to design, build, launch and ramp new High Pressure Die Casting manufacturing lines. This role will collaborate with product design, simulation, and process engineering and Operations to establish High Pressure Die Casting tooling requirements, creating fully detailed tooling design models for die fabrication by tooling suppliers.

Responsibilities:
Responsible for Engineering of Cast and Trim dies for all assigned High Pressure Die cast components

Proficient in die design with optimized runner & gate, thermally balanced inserts, and highest possible vacuum efficiency to produce structural components using water free lube

Manage die suppliers using Project Management best practices during die build programs, keeping project within time and budget

Create critical spares inventory with min, max, and order quantity

Able to read simulation reports with good understanding of flow simulation software such as Magma soft & Flow 3D

Optimize tooling performance by utilizing applicable surface coatings and materials to improve die life and reduce/eliminate soldering

Perform dimensional analysis; implement corrective actions to improve dimensional capability. Complete understanding of casting tolerances and GD&T

Involve in maintenance of dies by providing Engineering support as needed. Collaborate with Tool & Die team to address all production issues related to tooling. Maintain die design/documents database with timely updates as needed

Troubleshoot systematically for downtime and scrap issues using RCA methods Establish strong and positive working relationships with other departments Commitment to be a strong team player

Evaluate failures and provide technical solutions to improve quality and / or OEE in the specified area

Requirements:
Bachelor of Science in Mechanical, Industrial Engineering, Materials, Engineering, or related field or equivalent experience

Related experience in the High-Pressure Die-castings in the automotive industry Proficient in Die Design with experience in gating and thermal design

Proficient in 2D and GD&T, with 3D modelling with proficiency in CATIA V5

Experience with flow simulation software and Project Management skills

Exceptional understanding of the interactions between the high pressure die casting tooling conditions (e.g. die temperature, die & tip lube application, shot profile, etc.) influences the metallurgical and structural integrity of cast aluminum components

5+ years of experience in high pressure aluminum die casting tooling design, manufacturing engineering, process, equipment, robot programming and control systems

Experience developing manufacturing die casting dies for new and unique products

Experience defining and assessing quality standards associated with common manufacturing processes including drawing specifications, limit samples, and incoming/outgoing quality control points with a proven track-record of shepherding products from tool release to mass production

Experience with manufacturing process like injection molding, CNC, die casting, die assembly, and box build in a production setting and a good understanding of the costs and schedule, and complexity associated with each process

Fluent in the English language

Compensation & Benefits:
Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:
Medical plans > plan options with $0 payroll deduction
Family-building, fertility, adoption and surrogacy benefits
Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
Healthcare and Dependent Care Flexible Spending Accounts (FSA)
401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
Company paid Basic Life, AD&D
Short-term and long-term disability insurance (90 day waiting period)
Employee Assistance Program
Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
Back-up childcare and parenting support resources
Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
Weight Loss and Tobacco Cessation Programs
Tesla Babies program
Commuter benefits
Employee discounts and perks program