Sr. Tool Design Engineer, Pressure Die Casting

the company was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today the company is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.

the company is developing a low latency, broadband internet system to meet the needs of consumers across the globe. Enabled by a constellation of low Earth orbit satellites, Starlink will provide fast, reliable internet to populations with little or no connectivity, including those in rural communities and places where existing services are too expensive or unreliable.

Working directly in the materials engineering group, this position will primarily support manufacturing and development of the company’s Starlink product components alongside a strong group of mechanical and process engineers. The goal of the team is to develop new manufacturing methods, commission equipment and qualify processes to be introduced into production. As the Sr. Tool Design Engineer you will collaborate with product design, simulation, and process engineering, to establish high pressure die casting tooling requirements, creating fully detailed 3D CAD tooling design models for die fabrication by tooling suppliers.

• Develop the CAD design of new die cast tooling from concept through production, including split lines, slides, ejection, vent and cooling system (e.g. waterlines in tool steel as well as internal and external plumbing)
• Provide feedback to product design engineers to achieve the right balance between product performance and manufacturability from a tooling perspective (e.g. draft angles, rib/boss geometry, etc.)
• Incorporate input from flow and thermal simulation engineers into the die design
• Capture feedback from casting process engineers into new and replacement dies
• Invent new ideas to push the envelope of performance (cycle time, yield, uptime) and minimize risk
• Provide technical oversight of tooling suppliers
• Assist in the development of tooling design and fabrication schedules, then execute accordingly
• Manage product design, die design, and die fabrication timelines

• Bachelor’s degree in an engineering discipline
• 5+ years of professional mechanical design experience in high-pressure aluminum die casting tooling design

• Master’s degree or PhD in mechanical engineering or similar engineering discipline
• Experience with aluminum high vacuum, high pressure, thin wall structural die casting tool design
• Strong to expert level 3D CAD skills, including advanced surfacing and large assemblies
• Fluency with Siemens NX
• 8+ years high pressure die casting experience in a production environment
• Exceptional understanding of the interactions between the high pressure die casting process conditions (e.g. die temperature, die and tip lube application, shot profile, etc.)