Tooling & Die Design Engineer – HPDC

Tooling and Die Design Engineer

We are seeking a highly skilled Tooling and Die Design Engineer with 3 to 5 years of experience specialized in aluminum and magnesium high-pressure die casting (HPDC). This role bridges advanced simulation engineering with high-stakes customer collaboration. The ideal candidate will possess advanced capabilities in 3D flow and solidification modeling alongside outstanding communication and interpersonal skills. You will frequently work closely with client engineering teams—including on-site collaboration at their facilities—to optimize part designs for manufacturing and lead tooling development from concept to production launch.

• Tooling Design & Simulation Engineering
• Advanced Simulation:
  Utilize MAGMA5, FLOW-3D, or equivalent liquid flow modeling tools to perform comprehensive 3D flow, thermal, and solidification simulations.
• Die & Gating Design:
  Design and optimize complete die casting tooling layouts, including gating systems, runners, overflows, venting, and thermal management (cooling/heating) channels.
• Design for Manufacturing (DFM):
  Lead detailed DFM reviews, translating simulation results into concrete engineering recommendations for wall thicknesses, draft angles, fillets, and parting lines.
• Troubleshooting & Optimization:
  Analyze production tooling wear or casting defects and engineer permanent design modifications to improve die life and quality yields.
• OEM Customer Interface & Collaboration
• On-Site Technical Liaison:
  Embed with OEM customer engineering teams at their sites during early development phases to provide face-to-face technical support and build strong, trusting partnerships.
• Cross-Functional Communication:
  Translate complex fluid dynamics and metallurgical data into clear, actionable design feedback for both highly technical internal teams and external client stakeholders.
• NPI Support:
  Actively participate in prototype builds and early New Product Introduction (NPI) phases to ensure client expectations align perfectly with production realities.
• Documentation:
  Develop and maintain rigorous documentation for design changes, simulation logs, control plans, and customer design sign-offs.

• Experience:
  
  3 to 5 years of dedicated experience in tooling design and simulation engineering specifically for aluminum and/or magnesium high-pressure die casting.
• Education:
  
  Bachelor's degree in Mechanical Engineering, Metallurgical Engineering, Materials Science, or a related engineering discipline.
• Simulation Expertise:
  Proven proficiency running advanced 3D liquid flow and solidification modeling software (e.g., MAGMA, FLOW-3D).
• CAD Proficiency:
  Strong hands-on experience with 3D CAD design software (such as NX, Catia, or Creo).

• 3 to 5 years of hands-on experience working directly in the HPDC industry or within an Automotive OEM's product development team.
• Superior Communication:
  Excellent verbal and written communication skills in English, with the polished presence necessary to represent PSW Group directly on-site at major OEM facilities.
• Problem Solving & Adaptability:
  Excellent organizational skills, attention to detail, and the flexibility to balance shifting customer requirements with internal production capabilities.

This position will be based in Detroit, MI and will require travel to customer sites for on-site support. When customer visits are not required, the role may work remotely. One day per week will be required on-site at Magretech in Bellevue, OH.

• 30% domestic traveling and occasionally international travels.

• Primarily office-based with regular travel to manufacturing sites, supplier locations, and industry events.
• Occasional extended hours may be required to meet project deadlines and business needs.
• Most of the time is spent in an office setting outside of the production plant or warehouse center. The environment will include, at times walking onto the plant production floor where there is weather and non-weather-related hot or humid conditions, extreme cold, working near moving mechanical parts or equipment.
• The noise level in the work environment is quiet…