Sr. Foundry Process Engineer

Own the design, definition, implementation, and long-term sustainment of Melt Center processes that deliver consistent, high-quality molten aluminum to Tesla’s high-pressure die casting (HPDC) operations. Act as the technical authority for melting, holding, cleaning, and metal transfer — and providing clear process and design inputs for future melting, holding, and transfer systems.

Define furnace cleaning, fluxing, and metal-treatment practices that maximize melt quality, recover metal from dross, and extend refractory life, while leading adoption of new metal-cleaning concepts across the melt path Establish process requirements and operating standards for scrap loading, melting rate, holding practice, and quality gates before transfer to HPDC machines Collaborate with cross-functional teams to lock requirements (melt rate, transfer rate, cleaning frequency, loading cadence) for new and existing melting and transfer systems Drive functional requirements for metal transfer systems (pumps, auto-tappers, launders, ladles) and partner with stakeholders and OEMs so design-phase solutions meet operational, quality, and reliability needs Commission and troubleshoot new Melt Center equipment, verifying performance against melt rate, transfer rate, refractory life, and metal-quality targets Lead sustaining and continuous-improvement projects with Operations, Facilities, and Maintenance, with a primary focus on operational safety Translate process learnings into design inputs for next-generation melting, holding, and transfer systems

Degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, or equivalent combination of education and experience 10+ years in secondary aluminum foundry / melting operations (casthouse or melt center strongly preferred) Proven experience introducing new foundry equipment and processes into live production, with project management from concept through commissioning and sustainment Hands-on expertise across refractory systems and repairs, scrap loading, melting process control, metal cleaning/treatment, launder and ladle transfer, and dross processing Experience defining process workflows and driving floor-level implementation with Operations, Facilities, and Maintenance to solve problems and implement long-term solutions Experience designing manufacturing layouts and equipment interfaces in 2D (AutoCAD) and/or 3D (CATIA / SolidWorks) Strong written and verbal communication skills with technical and non-technical audiences

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