Senior Engineer - Design COE EV

Mahindra and Mahindra Limited [Automotive and Farm Equipment Business]; Chennai District; On-site; INR 700,000 - 1,100,000; Full time

Job summary

Mahindra and Mahindra Limited is seeking a skilled HPDC Component Designer with 3+ years' experience to lead die casting component design from concept through production. You will use Siemens NX for 3D modeling and drawings, perform tolerance stack-up analyses, and apply GD&T while coordinating with manufacturing and QA to ensure robust, scalable designs.

The role emphasizes DFMA principles, casting knowledge across aluminum, magnesium, and zinc alloys, and collaboration to deliver reliable,

Qualifications

• 3+ years in high pressure die casting component design.
• Bachelor’s degree in Mechanical Engineering or related field (preferred).
• Proficiency in Siemens NX 3D modeling and drawing preparation, including assembly modeling and drafting.

Responsibilities

• Create and optimize designs for die casting molds and components using NX 3D CAD software.
• Develop detailed 3D models and 2D drawings, ensuring compliance with industry standards and customer requirements.
• Design casting geometry based on functional, mechanical, and performance needs.
• Integrate die casting best practices: wall thickness, draft angles, undercuts, ribs, bosses, and snap-fits for moldability and structural integrity.
• Conduct feasibility studies, design calculations, and tolerance stack-up analysis to ensure manufacturability and performance.
• Support product development from initial design through prototyping, testing, and mass production.
• Perform engineering analyses including mechanical stress, thermal analysis, and FEA to validate designs.
• Run casting simulation software (e.g., Moldflow) to optimize part geometry and minimize defects such as porosity and warping.
• Collaborate with manufacturing, tooling, quality assurance, suppliers, and product management teams to define requirements and address DFM/DFA considerations.
• Prepare and maintain comprehensive engineering documentation: design specs, 3D models, 2D drawings, BOMs, test protocols, validation reports, and engineering change records.
• Communicate part measurements and design intent using GD&T.
• Establish and monitor key process parameters (metal temperature, shot speed, pressure, cooling time, die temperature).
• Troubleshoot and resolve casting and process-related issues.
• Document production costs and maintain up-to-date job history files.

Skills

NX 3D modeling

Drafting & assembly

Tolerance stack-up

GD&T

Moldflow

ProCAST

DFM/DFA

Education

BE/ME in Mechanical/Automobile Engineering

Tools

Moldflow

MAGMASOFT

ProCAST

Job description

Job Description:

Responsibilities & Key Deliverables

Position Summary

Seeking a skilled High Pressure Die Casting (HPDC) Component Designer with a minimum of 3 years’ experience in die casting component design and strong proficiency in Siemens NX 3D modeling and drawing preparation. The ideal candidate will possess foundational knowledge of tolerance stack-up analysis and Geometric Dimensioning and Tolerancing (GD&T), and will be responsible for the full lifecycle of die cast component design, from concept through production support.

Key Responsibilities

Design & Development

• Create and optimize designs for die casting molds and components using NX 3D CAD software.
• Develop detailed 3D models and 2D drawings, ensuring compliance with industry standards and customer requirements.
• Design casting geometry based on functional, mechanical, and performance needs.
• Integrate die casting best practices: wall thickness, draft angles, undercuts, ribs, bosses, and snap-fits for moldability and structural integrity.
• Conduct feasibility studies, design calculations, and tolerance stack-up analysis to ensure manufacturability and performance.
• Support product development from initial design through prototyping, testing, and mass production.

Experience

Qualifications

• Minimum 3 years’ experience in high pressure die casting component design.
• Bachelor’s degree in Mechanical Engineering or related field (preferred).

Industry Preferred

Qualifications

BE or ME in Mechanical/ Automobile Engineering

• Proficiency in Siemens NX 3D modeling and drawing preparation, including assembly modeling and standards-compliant drafting.
• Basic knowledge of tolerance stack-up analysis and GD&T (ASME Y14.5).
• Experience with casting simulation software (Moldflow, MAGMASOFT, ProCAST, etc.) is a plus.
• Familiarity with die casting materials (aluminum, magnesium, zinc alloys) and manufacturing processes.
• Understanding of DFM/DFA principles and die casting tooling design.

General Requirements

Technical Analysis & Simulation

• Perform engineering analyses including mechanical stress, thermal analysis, and FEA to validate designs.
• Run casting simulation software (e.g., Moldflow) to optimize part geometry and minimize defects such as porosity and warping.
• Interpret simulation results and recommend design improvements.

Collaboration & Documentation

• Collaborate with manufacturing, tooling, quality assurance, suppliers, and product management teams to define requirements and address DFM/DFA considerations.
• Prepare and maintain comprehensive engineering documentation: design specs, 3D models, 2D drawings, BOMs, test protocols, validation reports, and engineering change records.
• Communicate part measurements and design intent using GD&T.

Process Management & Improvement

• Establish and monitor key process parameters (metal temperature, shot speed, pressure, cooling time, die temperature).
• Troubleshoot and resolve casting and process-related issues.
• Document production costs and maintain up-to-date job history files.

Our commitment to Diversity, Equity, and Inclusion

At Mahindra and Mahindra Limited, we believe that diversity drives innovation, and inclusion is at the heart of everything we do. We are committed to cultivating a workplace where every individual feels valued, respected, and empowered to thrive.
We are proud to be an Equal Opportunity Employer. All qualified applicants will be considered for employment without regard to age, caste, race, religion, color, ethnic origin, gender identity, nationality, physical or mental disability, medical condition, sexual orientation, educational background, marital or domestic partnership status, pregnancy or childbirth, veteran status, citizenship status, ancestry, financial status, or any other personal characteristic protected by applicable law.
We actively encourage candidates from all backgrounds to apply and bring their unique perspectives to our teams. We are committed to ensuring an accessible and inclusive experience for all applicants.
Together, we rise by embracing differences and building a future that reflects the communities we serve.