Technical Manager- Advanced High Pressure Die Casting (HPDC)

PSW Group; Chicago (IL); On-site; USD 100,000 - 150,000; Full time

Benefits offered by this job

Competitive salary

Discretionary bonus

401k plan with company match

Medical, dental, vision coverage

Job summary

A leading magnesium and aluminum manufacturer is seeking a Technical Manager to lead technology development and customer collaborations. The role involves optimizing HPDC processes and tooling, performing modeling, and ensuring manufacturability. Candidates should have over 5 years of hands-on HPDC experience and a Bachelor's degree in Engineering. This full-time position offers a competitive salary and a comprehensive benefits package.

Qualifications

• 5+ years hands-on HPDC experience with proven responsibility for die design, process optimization, and pilot production.
• Proficiency in robot programming and integration for casting cells (ABB, FANUC, KUKA, or similar).
• Strong project management skills and experience leading multidisciplinary technical teams.

Responsibilities

• Lead hands-on development and optimization of HPDC, semi-solid casting processes, and tooling.
• Collaborate with toolmakers to develop tooling and lead troubleshooting efforts.
• Perform flow and solidification modeling to optimize casting processes.

Skills

Hands-on HPDC experience

Flow/thermal modeling tools

Project management

Robotics programming

Metallurgy for Al and Mg alloys

Problem-solving

Communication

Education

Bachelor’s degree in Mechanical, Materials, or Manufacturing Engineering

Tools

MAGMASOFT

FLOW-3D

Job description

Technical Manager – Advanced High Pressure Die Casting (HPDC)

Join PSW Group as a Technical Manager to lead technology development, pilot programs, and customer collaborations that strengthen PSW’s technical leadership and market presence.

PSW Group is a leading magnesium and aluminum manufacturer advancing nonferrous metal technologies. We are investing in a state‑of‑the‑art Advanced Casting Technology Development Center that will accelerate new HPDC, semi‑solid casting, and other technologies for aluminum and magnesium casting development. This center will drive next‑generation casting solutions for automotive, aerospace, consumer electronics, and other light‑metal industries.

Salary range: $100–150k base pay + performance bonuses.

Core Responsibilities

• Lead hands‑on development and optimization of HPDC, semi‑solid casting processes, tooling, and associated automation at the Technology Development Center.
• Own die design and validation: collaborate with toolmakers to develop tooling, perform detailed design and validation, and lead troubleshooting efforts.
• Perform and supervise flow and solidification modeling (e.g., MAGMASOFT, FLOW‑3D, etc.) to optimize casting process.
• Develop and validate process parameters for magnesium and aluminum alloys across various machine platforms and shot systems.
• Implement and optimize secondary processes (heat treatment, machining, surface finish, etc.) to meet functional and aesthetic requirements.
• Oversee robot programming, cell integration and automation for die handling.
• Lead pilot runs and scale‑up from lab to prototype and pre‑production, ensuring repeatability and manufacturability.
• Coordinate with supply chain and manufacturing to transfer validated processes, tooling and work instructions into production.
• Define acceptance criteria, run capability studies and support qualification activities with OEMs/Tier suppliers.
• Work closely with Technical Market Development and Ops to define customer requirements and translate them into technical solutions.
• Support customer trials, technical presentations, and on‑site demonstrations; prepare technical reports and proposals.

Qualifications

• Bachelor’s degree in Mechanical, Materials or Manufacturing Engineering.
• 5+ years hands‑on HPDC experience with proven responsibility for die design, process optimization, and pilot production.
• Demonstrable experience with flow/thermal/solidification modeling tools (MAGMA, FLOW‑3D or equivalent).
• Practical experience with die design, gating, venting, runner systems, and tooling troubleshooting.
• Proficiency in robot programming and integration for casting cells (ABB, FANUC, KUKA, or similar).
• Strong project management skills and experience leading multidisciplinary technical teams.
• Excellent problem‑solving, communication and stakeholder engagement abilities.
• Working knowledge of metallurgy for Al and Mg alloys, casting defects, and corrective actions.

Preferred

• Advanced degree in Mechanical, Materials or Manufacturing Engineering.
• Experience with Aluminum semi‑solid casting and Magnesium Thixomolding casting.
• Experience transferring processes from R&D/pilot to volume production in an automotive or aerospace supply chain.
• Prior engagements with OEMs/Tier 1 suppliers and knowledge of automotive qualification requirements.
• Working knowledge of sustainability frameworks and low‑carbon manufacturing strategies.

Work Environment

Primarily office‑based with regular travel to manufacturing sites, supplier locations, and industry events. Occasional extended hours may be required to meet project deadlines and business needs. Most of the time is spent in an office setting outside of the production plant or warehouse center, though the environment will include times walking onto the plant production floor where there is weather‑related hot or humid conditions, extreme cold, or working near moving mechanical parts or equipment. The noise level in the work environment is quiet in the office but can be loud when on the production floor, warehouse or loading areas. Frequently required to sit.

People Matter

PSW Group is dedicated to fostering an open, inclusive, and trusting culture where every employee feels valued and respected. We treat all our employees fairly and with respect and dignity, regardless of their position or background. We actively listen to our employees and provide them with honest, responsible feedback. The safety and well‑being of our employees is of utmost importance to us, and we strive to provide the safest working conditions possible.

Compensation & Benefits

Our employees are our greatest asset. We are committed to providing a comprehensive benefits package that helps our employees stay healthy, work‑life balanced and have a sense of security. The benefits package includes a competitive salary, discretionary bonus, the ability to participate in a 401k plan with company match, medical, dental, vision, life, disability and other types of group and individual coverages.

Vision

Committed to providing the highest quality raw materials.

Mission

To support our customers in building their products and be their trusted partner in innovation and success by providing superior and sustainable lightweight metal solutions.

About PSW Group

PSW Group is a leading recycler and producer of non‑ferrous lightweight metals, specializing in magnesium and aluminum. We supply a broad range of products including secondary magnesium alloys, primary and secondary aluminum alloys, and tolling and chip recycling services. Our international production facilities in North America, Europe, and Asia provide a cross‑continental network of reliable supply that is unrivaled in the industry. Our team also stands at the forefront of sustainability by investing in technologies and processes to reduce our carbon footprint while maintaining the highest quality of our products.

Equal Opportunity Employer

PSW Group is an equal opportunity employer committed to workplace diversity. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, age, gender identity, protected veterans’ status, status as a disabled individual or any other protected group status or non‑job characteristic as directed by law.

Seniority Level

Mid‑Senior level

Employment Type

Full‑time

Job Function

Engineering and Information Technology

Industry

Manufacturing