Tesla

Makes electric cars, robotaxis and grid batteries

Senior Foundry Process Engineer

Process EngineeringConfirmed live in the last 24 hours

Full-timeAustin, TX, USANo salary listedIn-person

About the Job

Requirements

A degree in Mechanical Engineering, Materials Science, or Metallurgical Engineering, or an equivalent combination of education and experience.
At least 10 years of experience in secondary aluminum foundry or melting operations; casthouse or melt center experience is strongly preferred.
Proven experience introducing new foundry equipment and processes into live production, including project management from concept through commissioning and sustainment.
Hands-on expertise with refractory systems and repairs, scrap loading, melting process control, metal cleaning and treatment, launder and ladle transfer, and dross processing.
Experience defining process workflows and driving floor-level implementation with Operations, Facilities, and Maintenance to solve problems and implement long-term solutions.
Experience designing manufacturing layouts and equipment interfaces in 2D using AutoCAD and/or in 3D using CATIA or SolidWorks.
Strong written and verbal communication skills with technical and non-technical audiences.

Responsibilities

Define furnace cleaning, fluxing, and metal-treatment practices to maximize melt quality, recover metal from dross, and extend refractory life, while leading adoption of new metal-cleaning concepts across the melt path.
Establish process requirements and operating standards for scrap loading, melting rate, holding practice, and quality gates before transfer to high-pressure die casting machines.
Collaborate with cross-functional teams to define requirements for melt rate, transfer rate, cleaning frequency, and loading cadence for new and existing melting and transfer systems.
Drive functional requirements for metal transfer systems, including pumps, auto-tappers, launders, and ladles, and partner with stakeholders and original equipment manufacturers so design-phase solutions meet operational, quality, and reliability needs.
Commission and troubleshoot new Melt Center equipment, verifying performance against melt rate, transfer rate, refractory life, and metal-quality targets.
Lead sustaining and continuous-improvement projects with Operations, Facilities, and Maintenance, focusing primarily on operational safety.
Translate process learnings into design inputs for next-generation melting, holding, and transfer systems.

Desired Qualifications

Casthouse or melt center experience.

Category	Manufacturing
Location	AUSTIN, Texas
Requisition ID	285020
Type	Full-time

Job Description

<div class="MSWordContent"><p>Own the design, definition, implementation, and long-term sustainment of Melt Center processes that deliver consistent, high-quality molten aluminum to Tesla’s high-pressure die casting (HPDC) operations. Act as the technical authority for melting, holding, cleaning, and metal transfer — and providing clear process and design inputs for future melting, holding, and transfer systems. </div>

Job Responsibilities

Define furnace cleaning, fluxing, and metal-treatment practices that maximize melt quality, recover metal from dross, and extend refractory life, while leading adoption of new metal-cleaning concepts across the melt path
Establish process requirements and operating standards for scrap loading, melting rate, holding practice, and quality gates before transfer to HPDC machines
Collaborate with cross-functional teams to lock requirements (melt rate, transfer rate, cleaning frequency, loading cadence) for new and existing melting and transfer systems
Drive functional requirements for metal transfer systems (pumps, auto-tappers, launders, ladles) and partner with stakeholders and OEMs so design-phase solutions meet operational, quality, and reliability needs
Commission and troubleshoot new Melt Center equipment, verifying performance against melt rate, transfer rate, refractory life, and metal-quality targets
Lead sustaining and continuous-improvement projects with Operations, Facilities, and Maintenance, with a primary focus on operational safety
Translate process learnings into design inputs for next-generation melting, holding, and transfer systems

Job Requirements

Degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, or equivalent combination of education and experience
10+ years in secondary aluminum foundry / melting operations (casthouse or melt center strongly preferred)
Proven experience introducing new foundry equipment and processes into live production, with project management from concept through commissioning and sustainment
Hands-on expertise across refractory systems and repairs, scrap loading, melting process control, metal cleaning/treatment, launder and ladle transfer, and dross processing
Experience defining process workflows and driving floor-level implementation with Operations, Facilities, and Maintenance to solve problems and implement long-term solutions
Experience designing manufacturing layouts and equipment interfaces in 2D (AutoCAD) and/or 3D (CATIA / SolidWorks)
Strong written and verbal communication skills with technical and non-technical audiences

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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