Exterior Structural Casting Technical Specialist

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A technical specialist role within Exterior Structural Castings, Vehicle Hardware Engineering, responsible for technical content, strategy, and processes. In this role, you will serve as the Technical Specialist for all casting-related matters ensuring robust design & delivery of components & vehicle systems.

This position will lead all technical aspects of Ford’s global Castings product strategy, including product concept development, business case approval, supplier and internal manufacturing partnerships, product development, verification & validation, launch/sign-off & ongoing support & quality assurance of products in the field. In addition, the Structural Casting technical specialist will develop & lead professional development of casting team members, oversee foundation document creation & enforcement of prevent recurrence, guiding development of Structural Casting standardized tools, methods & execution.

• Lead casting design, development and implementation for Structural Systems Engineering (BIW, Frames / Subframes, Battery Structures)
• Lead and develop a team of casting engineers to expand usage of high/low pressure die casting, thixo-casting/thixo-molding, and rheocasting technology across Ford & Lincoln vehicle lines
• Manage engineering team responsible for the forming simulation of casted designs to assess design impact of flow, fill, pressure and temperature distribution, and solidification. Utilize the data from the simulations to guide design changes and to aid in tooling and process development.
• Lead the development and management of all Engineering Specifications, Design Rules, Engineering Requirements, Virtual Test Methods, 1st Pick List and Modular Designs needed to support the design of high pressure die castings for vehicle structures Identify, develop, and implement new technologies to improve the efficiency of structural castings for vehicle structures
• Work with a cross functional team including personnel from product development, manufacturing, packaging, attributes and suppliers to develop designs for large structural castings for BIW, frame/subframe and battery structure applications on future vehicles.
• Guide the develop casting solutions that are efficient to manufacture that incorporate the features and functions of multiple stamped parts and reduces the complexity of our assembly operations.
• Support the development of actions to address issues related to achieving Noise, Vibration, and Harshness, Durability, and Safety performance objectives. Work closely with the analysis teams for each of the attributes to develop efficient solutions to any problems identified.
• Support the creation of design solutions and aid in the development of the manufacturing process to ensure part quality and performance are meet.
• Work with external suppliers and the Ford manufacturing team to meet the dimensional requirements of the casting component and final assembly.
• Sign off on designs prior to milestone completion to support component and vehicle analysis, and prior to production tool kick off.
• Sign off on final parts and assemblies’ prior…