Exterior Structural Castings Engineer

Ford; Dearborn, Northern (MI, KY); On-site; USD 74,000 - 166,000; Full time

Benefits offered by this job

Medical coverage, dental, vision

Family benefits

Vehicle discount program

Tuition assistance

Employee resource groups

Paid time off

Paid holidays

Hiring bonuses

Job summary

Ford Motor Company in Dearborn, MI seeks a Structural HPDC Casting Design Engineer to deliver CAD concepts, gating systems and manufacturability studies in support of BIW and frame designs. You will collaborate with cross-functional teams on vehicle packaging, validation (crash, durability, NVH) and drive improvements through simulations and process changes, mentoring peers in CAD and casting practices.

Ford offers comprehensive benefits, a hybrid work model, and opportunities to work with

Qualifications

• Bachelor's or higher in Mechanical, Materials or Manufacturing Engineering or related field.
• 5+ years of casting design experience.
• Ability to design solids in CAD (Catia, NX or 3DX).
• Ability to interpret simulation results (Magmasoft, Flow 3D, Procast) and improve the casting design.
• 20% travel is required, local and international.

Responsibilities

• Create casting designs to integrate multiple parts into one casting.
• Develop business cases for proposed casting solutions for management’s consideration.
• Provide direction on design or process changes to optimize casting for quality and cost.
• Support technical documentation including lessons learned and design rules in Ford internal system.
• Work with cross-functional teams for vehicle packaging compliance and issue resolution.
• Support less experienced engineers in CAD, tooling design and on-site casting quality assessment.

Skills

CAD

Casting design

Simulation interpretation

Education

Bachelor's or higher in Mechanical/Materials/Manufacturing Eng

Tools

Catia

NX

3DX

Magmasoft

Flow 3D

Procast

Job description

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life.We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

In this position...

This position is within our Product Development organization focused on the design and development of structural high pressure die cast (HPDC) components to support the future body in white (BIW) and frame designs. The engineer in this position will be responsible for generating HPDC structural casting design solutions, including CAD concepts of castings, gating systems, overflows while checking for manufacturing feasibility.

You will also work with cross functional teams for vehicle attribute validation including crash safety, durability and NVH, and will make changes to the casting to improve the results as required. The engineer will also provide technical support during the execution and industrialization phase of the program, generate Core engineering documentation to continuously improve our casting systems, support other less experienced engineers with CAD capabilities, manufacturing casting experience and interpretation of simulation results. Casting design experience is required.

You will be part of the Structural Castings team responsible for delivering casting solutions for Ford’s Global programs, and with a unique opportunity to influence Ford’s growth in the casting space, being involved in exciting new casting technology like Rheocasting and Thixomolding.

What you'll do...

• Create casting designs to integrate multiple parts into one casting.
• Develop business cases for proposed casting solutions for management’s consideration
• Provide direction on design or process changes needed to optimize the casting process for maximum quality and cost efficiency.
• Support technical documentation including lessons learned, best practices, design rules, design requirements and keep them updated in the Ford internal system.
• Work with cross functional teams for vehicle packaging compliance and issue resolution
• Support less experienced engineers in CAD, tooling design and on-site casting quality assessment for prototype part buy-off, including suggestions on how to improve the casting at a process or tooling level.
• Support external suppliers and tool shops with process and tooling verification prior to production startup.

You’ll have...

Minimum Requirements:

• Bachelor's or higher-level degree in Mechanical, Materials or Manufacturing Engineering or a related field
• 5+ years of casting design experience
• Ability to design solids in CAD (Catia, NX or 3DX)
• Ability to interpret simulation results (Magmasoft, Flow 3D, Procast, etc) and improve the casting design based on those.
• 20% travel is required, local and international

Even better, if you have …

Preferred

• Proficiency in CAD
• Experience working in a foundry or tool shop launching castings or HPDC tools in a manufacturing environment.
• Experience in large structural castings including Giga / Mega casting sizes
• Experience working on Thixomolding or Rheocasting technology
• Strong analytical and organizational skills and ability to manage several projects at the same time in a highly variable and uncertain environment.
• Strong communication skills, both written and oral.
• Microsoft Office experience.

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp‑up programs, subsidized back‑up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is a salary grade 6-8 and ranges from $74,300 - $166,200.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid. Candidates who are in commuting distance to a Ford hub location may be required to be onsite four or more days per week.