Sr. Advanced Manufacturing Engineer, Castings and Metal Forming, Advanced Manufacturing Engineering (AME)

Description

Amazon Robotics is seeking a Sr. Manufacturing Engineer with deep metal casting expertise to join our Advanced Manufacturing Engineering (AME) team in Westborough, MA. You will own manufacturing readiness for the cast structural and drivetrain parts in our robotic systems, from design-for-casting reviews through tool launch, qualification and production ramp at our global supplier base.

The Amazon Robotics (AR) Operations organization manufactures high-quality robotics and gets the right materials to the right place at the right time to enable our automated solutions. It's a fast-paced operation that works cross-functionally with teams across Amazon globally, and is powered by data and performance indicators.

Are you inspired by invention? Is problem solving through teamwork in your DNA? Do you like the idea of seeing how your work impacts the bigger picture? Answer yes to any of these and you'll fit right in here at Amazon Robotics. We are a smart team of doers that work passionately to apply manufacturing technology in robotics and software to solve real-world problems that will transform our customers' experiences. We invent new improvements every day. We will give you the tools and support you need to invent with us in ways that are rewarding, fulfilling and fun.

This role will report to the Head of Advanced Manufacturing Engineering. You will be AME's technical owner for castings across multiple new product introduction (NPI) programs. You will choose the right casting process for each part, set the requirements our suppliers build to, launch die-cast and cast tooling on aggressive schedules, and drive root cause on casting defects in production and the field. The successful candidate brings years of hands-on time at foundries or die casters and is willing to "roll up sleeves and do what needs to get done" to consistently deliver results.

The strongest candidates bring 5+ years of casting process or tooling engineering at a die caster, foundry or OEM casting program, covering high-pressure die casting (HPDC) or another production casting process, plus hands-on tool launches through production part approval process (PPAP).

Key job responsibilities
- Own casting manufacturing readiness from NPI through production ramp across high-pressure die casting (HPDC), low-pressure, gravity, investment and sand casting in aluminum, magnesium, zinc and ferrous alloys.
- Lead process selection and make-vs-convert trade studies (casting vs. billet, fabrication, extrusion or molding) on cost, lead time, tooling investment and capability.
- Provide design for casting feedback on draft, wall thickness, ribbing, parting lines, gating, ejector placement, datums and machining stock.
- Review mold-flow and solidification simulation (MAGMASOFT, ProCAST, FLOW-3D CAST) before tool steel is cut.
- Launch die-cast and cast tooling on accelerated schedules: tool design reviews, press tonnage, trim tooling, fixtures and T0/T1 trials.
- Qualify casting processes through first article inspection, PPAP, control plans and process capability (Cpk), including machining, heat treatment, impregnation and finishing.
- Set casting quality requirements: porosity classes, X-ray or CT acceptance, mechanical testing, leak testing and CMM inspection.
- Drive failure analysis and corrective action on porosity, cold shuts, hot tears, soldering and distortion using 8D and 5-Why.
- Lead PFMEA and DFMEA reviews, and evaluate Engineering Change Orders (ECOs) on cast and machined parts.
- Develop casting suppliers across North America, Mexico and Asia.
- Up to 30% travel required, including international supplier sites.

A day in the life
You might start the day reviewing a solidification simulation for a new aluminum housing and pushing back on a thick boss that will shrink. Mid-morning, you join a design review with Hardware Engineering to move a parting line and add draft before the part releases. After lunch, you could walk a die caster through T1 X-ray results, disposition an ECO on a machined casting, or lead a PFMEA on a new trim process.

About the team
Advanced Manufacturing Engineering (AME) is Amazon Robotics' scalability engine, bridging innovation with execution. We integrate Design for Excellence principles early in the engineering process to accelerate product development and ensure globally scalable robotic solutions. Our team owns DfX leadership, supplier process qualification, manufacturing readiness assessments, and engineering change evaluation across the product lifecycle. We work cross-functionally with Hardware Engineering, Supply Chain, and Quality to transform concepts into production-ready systems that deploy reliably at scale.

Basic Qualifications

- Experience in developing functional specifications, design verification plans and functional test procedures
- Bachelor's degree or above in Industrial, Mechanical, Civil Engineering or other related discipline
- 8+ years of including new product introduction (NPI) experience
- Experience developing and executing test procedures for mechanical or electrical systems/components based on design intent and approved equipment submissions
- Broad manufacturing commodity background (Mechanical and Electrical).
- Familiarity with industry standard tools for problem solving and risk management.

Preferred Qualifications

- Experience working with interdisciplinary teams to execute product design from concept to production
- Master's degree in Engineering or Business Administration or a related field
- Deep commodity experience with one or more of the following: DC Gearmotors/encoders; Plastics (primarily injection molding); Metals (Stamping, Machining); Printed Circuit Board Assemblies, Sensors, Cameras; Cables.
- Experience with SPC, Gauge R&R, and PFMEA/DFMEA methodologies.
- Familiarity with PLM systems (Agile, Windchill, or equivalent) and engineering change management processes.
- Experience with complex automated material handling equipment, packaging technologies, and systems and high-speed manufacturing

Amazon is an equal opportunity employer and does not discriminate on the basis of protected veteran status, disability, or other legally protected status.

Our inclusive culture empowers Amazonians to deliver the best results for our customers. If you have a disability and need a workplace accommodation or adjustment during the application and hiring process, including support for the interview or onboarding process, please visit https://amazon.jobs/content/en/how-we-hire/accommodations for more information. If the country/region you’re applying in isn’t listed, please contact your Recruiting Partner.

The base salary range for this position is listed below. Your Amazon package will include sign-on payments and restricted stock units (RSUs). Final compensation will be determined based on factors including experience, qualifications, and location. Amazon also offers comprehensive benefits including health insurance (medical, dental, vision, prescription, Basic Life & AD&D insurance and option for Supplemental life plans, EAP, Mental Health Support, Medical Advice Line, Flexible Spending Accounts, Adoption and Surrogacy Reimbursement coverage), 401(k) matching, paid time off, and parental leave. Learn more about our benefits at https://amazon.jobs/en/benefits .

USA, MA, Westborough - 137,300.00 - 185,700.00 USD annually