Senior Arch Casting Simulation Engineer

Ford Motor Company; Dearborn (MI); On-site; USD 80,000 - 110,000; Full time

Job summary

Ford Motor Company is seeking a Casting Simulation Engineer to pioneer innovative casting strategies for electric vehicle platforms. The successful candidate will leverage expertise in CAD software and casting processes to deliver high-quality production outcomes. Join a dynamic team dedicated to shaping the future of automotive manufacturing while enjoying extensive benefits, including medical coverage and tuition assistance.

Benefits

Immediate medical, dental, and prescription drug coverage

Flexible family care and parental leave

Tuition assistance

Paid time off for community service

Paid holidays including the week between Christmas and New Year’s

Qualifications

• 5+ years' experience in high-volume casting simulation (automotive preferred).
• Experience with AI/machine learning in manufacturing is a plus.
• Strong understanding of casting processes and materials.

Responsibilities

• Develop casting simulation strategies for EV platforms.
• Optimize flow and solidification analysis using simulation tools.
• Collaborate with part leads from concept to production.

Skills

Strong analytical skills

Problem-solving skills

Collaboration skills

Education

BS/MS in Mechanical Engineering

Tools

Magmasoft

Flow3D

3D CAD software

Job description

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves, and build a better world — together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves?

Ford’s Electric Vehicles, Digital and Design (EVDD) team is charged with delivering the company’s vision of a fully electric transportation future. EVDD is customer-obsessed, entrepreneurial, and data-driven, dedicated to delivering industry-leading customer experience for electric vehicle buyers and owners. Join an agile team of doers pioneering our EV future by working collaboratively, staying focused on what matters, and delivering excellence daily. Join us to make positive change by helping build a better world where every person is free to move and pursue their dreams.

Qualifications

You'll have...

• BS/MS in Mechanical Engineering, Materials Science, or related field; 5+ years' experience in high-volume casting simulation (automotive preferred).

• 3+ years' experience with 3D CAD software (collaborative experience).

• Strong understanding of casting processes, materials, and techniques.

• Expertise in setting up and optimizing flow analysis using Magmasoft and Flow3d.

• Strong analytical skills and experience with CAE tools (casting simulation).

• Experience with alloy selection and casting process parameters.

• Experience with AI/machine learning in manufacturing (a plus).

• Systems approach to design and development; commitment to continuous improvement.

• Experience with GD&T and relevant industry standards.

• Strong analytical/problem-solving skills; detail-oriented and highly motivated.

• Excellent communication and collaboration skills.

You may not check every box, or your experience may look a little different from what we've outlined, but if you think you can bring value to Ford Motor Company, we encourage you to apply.

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 change maker, 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, and prescription drug coverage

• Flexible family care, parental leave, new parent ramp-up programs, subsidized back-up child care, 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.

For a detailed look at our benefits, click here: https://corporate.ford.com/content/dam/corporate/us/en-us/documents/careers/2024-benefits-and-comp-GSR-sal-plan-2.pdf

Visa sponsorship is available for this position.

Candidates must be legally authorized to work in the United States. Verification of employment eligibility will be required at hire.

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

Responsibilities

What you’ll do...

• Develop and implement casting simulation strategies for future EV platforms, collaborating with part leads from concept to mass production.

• Set up and optimize flow and solidification analysis using Magmasoft and Flow3d to predict and improve casting quality.

• Integrate flow analysis results with 3D casting designs, considering die life, cooling, material flow, and part distortion, collaborating with part leads.

• Use simulation tools to predict casting defects, optimize casting processes, including shot profile, cycle time, cooling, and part manufacturability.

• Optimize casting and part designs through analytical assessments, maximizing die life, minimizing cycle times, and improving quality via feedback between casting and design.

• Develop and implement advanced casting technologies (e.g., gating systems, die cooling, spray, extraction, quench strategies) based on simulation results, collaborating with material scientists.

• Optimize alloys to enhance die life and part performance, working with part leads for material choices based on simulation data.

• Create predictive models to maximize die life, considering part design impacts and simulation results.

• Apply AI/machine learning for data-driven process optimization, addressing quality issues, part distortion, and equipment efficiency, informing design and die life improvements.

• Participate in design reviews, presenting casting simulation results, concepts, and recommendations.

• Work cross-functionally to resolve technical challenges related to casting.

• Develop tools and methods to accelerate casting and part development, integrating CAE analysis for vehicle attributes.

• Troubleshoot prototype and production issues, collaborating with part leads using simulation as a key tool.

• Maintain design records, including simulation reports and validation data.