Tesla

Makes electric cars, robotaxis and grid batteries

Mechanical Design Engineer - Flow Simulations, Die Shop

Thermal & Fluids EngineeringConfirmed live in the last 24 hours

Full-timeAustin, TX, USANo salary listed

About the Job

Requirements

A degree in Mechanical Engineering, Materials Engineering, or a closely related field focused on Computational Fluid Dynamics, or equivalent experience.
At least 3 years of experience in structural high-pressure aluminum die casting processes and/or runner and vacuum design.
A strong understanding of how high-pressure die casting process conditions, including die temperature and shot profile, interact with part properties.
Proficiency in computer-aided design, with expertise in computational fluid dynamics and simulation; CATIA V5 or later is preferred, as are tools such as Flow-3D and Magma.
Experience transitioning high-volume products from concept to production.
Experience using statistical process control and root cause analysis in a high-pressure die casting manufacturing plant.
An in-depth understanding of how die design affects die life and casting cost.
Ability to travel up to 15% domestically and internationally.

Responsibilities

Design and develop runner systems for structural high-pressure die-casting dies, including gates, overflows, vacuum, heating, and cooling.
Perform calculations for fill time, gate area, venting area, tonnage, and related metrics.
Define initial parameters for process development, including shot profile, injection temperature, and thermal set points.
Perform casting-flow and thermal simulations to support the design and development of systems, including metal flow, thermal management, and stress analysis.
Use process and experimental data to refine simulations, tooling designs, and the casting process.
Lead the product design-for-manufacturing process in collaboration with part designers and die design engineers.
Provide foundry support during startup and process development for new casting programs.

Desired Qualifications

Proficiency with CATIA V5 or later.
Experience with Flow-3D, Magma, or similar simulation tools.

Category	Manufacturing
Location	AUSTIN, Texas
Requisition ID	284591
Type	Full-time

Job Description

The Die Shop is part of the Materials Engineering group responsible for the build, launch and handover of Tesla’s high pressure die casting dies, used for vehicle programs. This team is focused on achieving the highest efficiency, manufacturing volume and safety. As a Mechanical Design Engineer for the Die Shop, you will specialize in casting flow and thermal simulations, and will work in the team that designs Tesla’s Giga Casting dies. This is a casting process and tooling role focused on how structural aluminum die cast parts are filled, gated, and thermally managed. The work combines design, calculation, and simulation with feedback from real process results to improve both the die and the process. This position requires 15% domestic and international travel.

Job Responsibilities

Design and develop runner systems for structural high-pressure die cast dies (including gates, overflows, vacuum, heating and cooling
Perform essential calculations for fill time, gate area and venting area, tonnage, and similar metrics
Define initial parameters for beginning of process development (shot profile, injection temperature, thermal set points)
Perform casting flow and thermal simulations to support the design and development of these systems - including metal flow, thermal management, stress analysis, etc.
Use process and experimental data to fine-tune and improve simulations in order to continuously improve the tooling designs and improve the casting process
Take a leadership role in the product DFM process, working with part designers and die design engineers
Provide foundry support during startup and process development for new casting programs

Job Requirements

Degree in Mechanical Engineering, Materials Engineering or a closely related field focused on Computational Fluid Dynamics (CFD), or equivalent experience
3+ years of experience in structural high-pressure aluminum die casting processes and/or runner and vacuum design
Exceptional understanding of the interactions between the high-pressure die casting process conditions (die temperature, shot profile, etc.) and the properties of parts
Proficiency in CAD (CATIA V5+ preferred) with expertise in CFD and simulation (Flow-3D, Magma etc.)
Experience transitioning high-volume products from concept to production
Experience using statistical process control and root cause analysis in a high pressure die casting manufacturing plant
In-depth understanding of impact of the die design on die life and cost of casting
Ability to travel up to 15% domestic and international

About the Company

Tesla

Makes electric cars, robotaxis and grid batteries

Tesla makes electric cars and batteries that store power for homes and utilities, and it develops self-driving software and humanoid robots. In 2023, its Model Y became the first electric vehicle to rank as the world's best-selling car. Buyers order the Model 3 sedan, Model Y SUV, or Cybertruck pickup directly from Tesla instead of through dealers, and they charge on its Supercharger fast-charging network. It also sells Megapack and Powerwall batteries, runs a robotaxi service, and charges drivers a monthly fee for self-driving software that still needs their supervision. Tesla was founded in 2003, with Elon Musk as its lead early investor and a recognized co-founder, and it is based in Austin, Texas.

Company size: 10,001+
Company stage: IPO
Headquarters: Austin, TX
Founded: 2003

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