Global Die Cast Tooling Engineer

Magna International Limited; Kędzierzyn-Koźle; On-site; PLN 180,000 - 240,000; Full time

Benefits offered by this job

Seniority bonus

Performance bonus

MAGNA Employee Shares Program

Private healthcare

Sports card

Training and professional development

Job summary

Magna International Limited, Cosma International division, seeks a tooling engineer to design and optimize die cast tooling for HPDC processes. You will develop tooling improvements, design cooling and vacuum systems, and support global casting operations to improve yield and reduce costs.

Experience in aluminum HPDC, GD&T, and CAD tools is essential. The role involves cross-site collaboration, process optimization, and adherence to DFMEA/DFM methodologies to drive FTP objectives.

Qualifications

• Bachelor's degree in Engineering or related technical field.
• Several years of experience in aluminum casting, including HPDC.
• Strong knowledge of die cast tooling design principles and manufacturing processes.
• Experience with die design, runner systems, cooling system design, and vacuum technologies.
• Ability to assess manufacturing feasibility from engineering drawings and assemblies.
• Hands-on experience in process optimization and troubleshooting within a manufacturing environment.
• Proficiency in 2D and 3D CAD software, including AutoCAD, NX, and Spinfire.
• Knowledge of GD&T, gating and runner design, DFM, VE, DFMEA/PFMEA.
• Structured problem-solving techniques.
• Familiarity with MAGMASOFT or Flow-3D is preferred.
• Excellent English communication skills.

Responsibilities

• Design and optimize die cast tooling, including runner systems, cooling circuits, vacuum systems, seals, and trim tools to achieve superior casting quality, productivity, and yield.
• Develop and implement tooling improvements, including hydraulic cores, slides, squeeze cores, and jet-cooled cores to enhance manufacturing performance.
• Design cooling and vacuum solutions that support optimal cycle times, thermal balance, and process stability.
• Provide technical support to global casting operations by optimizing tooling performance through advanced materials, coatings, and best practices that improve die life and reduce soldering.
• Develop and maintain global tooling standards focused on increasing production performance, maximizing casting yield, and reducing tooling costs.
• Analyze thermal and dimensional performance of tooling and implement corrective actions to improve product quality and process capability.
• Apply Design for Manufacturability (DFM) principles to evaluate casting and tooling feasibility during product development.
• Utilize proactive engineering methodologies, including FMEA, Risk Assessments, and Lessons Learned, to support successful product launches and achieve First Time Pass (FTP) objectives.
• Collaborate closely with casting divisions to correlate simulation results with production trials and drive continuous process improvements.
• Analyze GD&T requirements and support the development of standardized tolerance strategies for structural die cast components.
• Work with tooling suppliers globally to optimize tooling concepts, costs, and lead times.
• Utilize engineering software and CAD tools to standardize casting feasibility analyses, engineering calculations, and tooling design methodologies.
• Partner with customers and internal stakeholders to finalize product designs and technical specifications that meet quality, productivity, cost, and delivery targets.
• Manage CAD data systems for products, tooling, fixtures, and manufacturing equipment while supporting knowledge sharing and documentation of lessons learned across global operations.
• Drive benchmarking activities and implement tooling best practices across global casting facilities.
• Provide process design, troubleshooting, Value Analysis/Value Engineering (VA/VE), trim tooling, and downstream manufacturing feasibility support to casting divisions worldwide.
• Participate in new product and process development initiatives focused on innovation, cost reduction, and operational excellence.

Skills

Aluminum casting

HPDC (High Pressure Die Casting)

Die cast tooling design

CAD (AutoCAD, NX, Spinfire)

DFM/VE/DFMEA/PFMEA

GD&T

Casting simulation (MAGMASOFT/Flow-3D)

English communication

Education

Bachelor's degree in Engineering or related field

Tools

MAGMASOFT

Flow-3D

CAD software interoperability

Job description

Magna International Limited, Cosma International division, seeks a tooling engineer to design and optimize die cast tooling for HPDC processes. You will develop tooling improvements, design cooling and vacuum systems, and support global casting operations to improve yield and reduce costs.

Experience in aluminum HPDC, GD&T, and CAD tools is essential. The role involves cross-site collaboration, process optimization, and adherence to DFMEA/DFM methodologies to drive FTP objectives.