Design Engineer- Casting

ALTEN India; Chennai District; On-site; INR 1,200,000 - 1,800,000; Full time

Benefits offered by this job

Global aerospace clients

Innovation-driven environment

Continuous learning

Collaborative workplace

Job summary

ALTEN India is seeking a Casting Parts Design Engineer in Chennai with 4-8 years of experience in automotive EV products. You will design aluminum and magnesium cast components for eAxle, HV motor, inverter, and related assemblies, creating detailed CATIA V5 models and drawings while refining systems with CAE and suppliers.

The role emphasizes DFM/DFA, GD&T per ASME Y14.5, tolerance stack-up analysis, and PLM data management, supporting prototype through production stages in a collaborative

Qualifications

• Must have hands-on experience in casting component design for automotive EV products.
• Proficient in CATIA V5 (Part Design, Assembly, Drafting) and GD&T.
• Knowledge of HPDC, gravity, and sand casting processes and related QA methods.

Responsibilities

• Design and develop aluminum and magnesium cast components for EV products.
• Create detailed 3D models and drawings using CATIA V5 / 3DEXPERIENCE.
• Develop cast housings, covers, brackets, motor casings, and structural components.
• Perform parametric modeling using skeleton and Boolean methodologies.
• Apply DFM/DFA guidelines for casting processes.
• Define GD&T as per ASME Y14.5 standards.
• Conduct tolerance stack-up analysis.
• Work with CAE, manufacturing, tool design, and suppliers.
• Support prototype, tooling, validation, and production activities.
• Manage product data in PLM systems.

Skills

Casting design

CATIA V5

HPDC

Gravity die casting

Sand casting

GD&T

Tolerance analysis

DFM/DFA

Core & cavity concept

Draft angle optimization

Wall thickness optimization

Education

B.E./B.Tech Mechanical Engineering

Tools

Teamcenter

Enovia

3DX

Job description

Casting Parts Design Engineer (4-5 Years & 5-8years) – Automotive EV Products

• Design and develop aluminum and magnesium cast components for eAxle, Reducer, HV Motor, HV Inverter, OBC/DCDC, Actuators, and related EV products.
• Create detailed 3D models and drawings using CATIA V5 / 3DEXPERIENCE.
• Develop cast housings, covers, brackets, end shields, motor casings, gearbox casings, and structural components.
• Perform parametric modeling using skeleton and Boolean methodologies.
• Apply DFM/DFA guidelines for casting processes.
• Define GD&T as per ASME Y14.5 standards.
• Conduct tolerance stack-up analysis.
• Work closely with CAE, manufacturing, tool design, and suppliers.
• Support prototype, tooling, validation, and production activities.
• Manage product data in PLM systems.

Job Role

Casting Parts Design Engineer (4-5 Years & 5-8years) – Automotive EV Products

Experience: 4-5 Years

Industry: Automotive / EV / Powertrain

Location: Chennai

Roles & Responsibilities

• Design and develop aluminum and magnesium cast components for eAxle, Reducer, HV Motor, HV Inverter, OBC/DCDC, Actuators, and related EV products.
• Create detailed 3D models and drawings using CATIA V5 / 3DEXPERIENCE.
• Develop cast housings, covers, brackets, end shields, motor casings, gearbox casings, and structural components.
• Perform parametric modeling using skeleton and Boolean methodologies.
• Apply DFM/DFA guidelines for casting processes.
• Define GD&T as per ASME Y14.5 standards.
• Conduct tolerance stack-up analysis.
• Work closely with CAE, manufacturing, tool design, and suppliers.
• Support prototype, tooling, validation, and production activities.
• Manage product data in PLM systems.

Required Technical Skills

• CATIA V5 (Part Design, Assembly, Drafting)
• Casting Design
• High Pressure Die Casting (HPDC)
• Gravity Die Casting
• Sand Casting
• Core & Cavity concept understanding
• Draft Angle, Rib, Boss, Wall Thickness optimization
• Shrinkage and Machining Allowance knowledge
• GD&T
• Tolerance Stack-up
• DFM/DFA
• PLM Tools (Teamcenter / Enovia / 3DX)

Manufacturing Knowledge

• Aluminum Die Casting
• Magnesium Casting
• Injection Molding (added advantage)
• Machining Process Understanding
• Surface Treatment and Coating Requirements

Preferred Product Experience

• eAxle Housing
• Reducer Housing
• HV Motor Housing
• HV Inverter Housing
• OBC/DCDC Enclosure
• Actuator Housing
• Cooling System Components

Education

• B.E./B.Tech Mechanical Engineering

Education

• B.E./B.Tech Mechanical Engineering

Why Join ALTEN India?

• Opportunity to work with leading global aerospace clients.
• Dynamic, innovation-driven environment with exposure to cutting-edge technologies.
• Continuous learning and career growth opportunities.
• Inclusive and collaborative workplace culture.