Sr. Mechanical Design Engineer, Flow Simulations, Die Shop

The Die Shop is part of the Materials Engineering group responsible for the build, launch and handover of Tesla’s high pressure die casting dies, used for vehicle programs. This team is focused on achieving the highest efficiency, manufacturing volume and safety.

As a Mechanical Design Engineer for the Die Shop, you will specialize in casting flow and thermal simulations, and will work in the team that designs Tesla’s Giga Casting dies. This is a senior casting process and tooling role focused on how structural aluminum die cast parts are filled, gated, and thermally managed. The work combines design, calculation, and simulation with feedback from real process results to improve both the die and the process. This position requires 15% domestic and international travel.

- Design and develop runner systems for structural high-pressure die cast dies (including gates, overflows, vacuum, heating and cooling
- Perform essential calculations for fill time, gate area and venting area, tonnage, and similar metrics
- Define initial parameters for beginning of process development (shot profile, injection temperature, thermal set points)
- Perform casting flow and thermal simulations to support the design and development of these systems - including metal flow, thermal management, stress analysis, etc.
- Use process and experimental data to fine-tune and improve simulations in order to continuously improve the tooling designs and improve the casting process
- Take a leadership role in the product DFM process, working with part designers and die design engineers
- Provide foundry support during startup and process development for new casting programs

- Degree in Mechanical Engineering, Materials Engineering or a closely related field focused on Computational Fluid Dynamics (CFD), or equivalent experience
- 5+ years of experience in structural high-pressure aluminum die casting processes and/or runner and vacuum design
- Exceptional understanding of the interactions between the high-pressure die casting process conditions (die temperature, shot profile, etc.) and the properties of parts
- Proficiency in CAD (CATIA V5+ preferred) with expertise in CFD and simulation (Flow-3D, Magma etc.)
- Experience transitioning high-volume products from concept to production
- Experience using statistical process control and root cause analysis in a high pressure die casting manufacturing plant
- In-depth understanding of impact of the die design on die life and cost of casting
- Ability to travel up to 15% domestic and international

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