Sr. Mechanical Design Engineer, Castings

What to Expect
The Castings Manufacturing Engineering Group is the part of the Materials Engineering Group responsible for the design, build, launch and handover of state of the art Casting lines and equipment currently used for vehicle and humanoid programs. This team is focusing on achieving the highest efficiency, manufacturing volume and safety while proving performance and documenting every aspect of the project for handover to sustaining.
The successful candidate for this role applies machine design fundamentals to the equipment, fixtures, and tooling on a high-volume manufacturing line, from concept through build-to-print, launch, and commissioning. The candidate must have experience taking functional requirements of a product or system and abstracting them into measurable and actionable design criteria with minimal guidance. You will own the detailed design of specialized equipment from beginning to end, defining performance requirements, performing simulations as needed to verify and align with first principles solutions and owning the commissioning including final validation. This position requires 10% travel.

What You’ll Do

• Apply machine design fundamentals to cell equipment, including loads, stiffness, mechanisms, fits, and service access, from concept through launch
• Design fixtures from a part drawing and CAD, including location, clamp, and clearance, and release the build-to-print package
• Detail robot tooling and end-of-arm equipment for material handling, including the robot interface, part location, wear, and changeover
• Design scrap handling equipment that keeps the cell clear, serviceable, and safe
• Support die design with the internal die team and external vendors, including interface, clearance, datum, access, and design-review management
• Design part trays, bins, and dunnage for transport between operations
• Own mechanical line design for the assigned equipment: concept, layout, supplier design review, installation support, and launch
• Produce 3D models and build-to-print drawings with GD&T that a shop or supplier can fabricate from
• Write the design basis, interface requirements, and buyoff criteria so the hardware can be built and sustained
• Providing supporting design validation analysis (FMEA, FEA, CFD, etc.) and detailed build to print models/drawings for fabrication

What You’ll Bring

• Degree in Mechanical Engineering or a similar field, or equivalent experience
• 5+ years designing mechanical equipment, tooling, or fixtures for high-volume manufacturing
• Ability to apply machine design fundamentals to released equipment, not only to concepts
• Ability to design a fixture and part handling tooling from a part model and drawing
• Proficiency in 3D CAD (Solid Works, NX, CATIA preferred) and GD&T, including drawings a supplier can build from
• Apply mechanical safety awareness at the hardware interface, including access, pinch points, and the guarding interface
• Competence in ISO 12100 Safety Standards for risk assessment and safety of machinery
• Experience working with tooling or equipment suppliers through design review and into build
• Clear written and verbal communication across design, supplier, and operations partners
• Ability to travel up to 10%