Arch Casting Simulation Engineer

About the position

This position focuses on the development and optimization of casting simulation for automotive body-in-white (BIW) structural components. The successful candidate will be responsible for setting up and optimizing flow analysis to ensure optimal casting design for manufacturability and part quality. This role requires close collaboration with part leads throughout the entire product lifecycle and integrating flow analysis with design development. The goal is to iteratively optimize both the casting process and the part design for best-in-class manufacturing efficiency and quality.

Responsibilities

• 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, balancing construction, material selection, and manufacturing methods.
• Collaborate with part leads to ensure part design considerations are fully integrated, addressing die life, cooling, material flow, and part distortion.
• Utilize simulation tools to predict casting defects, optimize casting process including shot profile, cycle time, optimize cooling, minimize part distortion, and ensure part manufacturability.
• Optimize casting and part designs using analytical assessments, maximizing die life, minimizing cycle times, and improving part quality through continuous feedback between casting and part design.
• Develop and implement advanced casting technologies (e.g., gating systems, die cooling, spray, extraction, and quench strategies) based on simulation results.
• Collaborate with material scientists for optimal material selection.
• Optimize alloys to enhance die life and part performance, collaborating with part leads for optimal material choices, informed by simulation data.
• Develop and use predictive models to maximize die life, considering part design impacts and simulation results.
• Integrate and apply AI/machine learning for data-driven optimization of the casting process, addressing quality issues, part distortion, and OEE.
• Participate in design reviews, presenting casting simulation results, integrated casting and part design concepts, and recommendations.
• Work cross-functionally to overcome technical challenges related to casting.
• Develop tools and methods for faster casting and part development, feeding CAE analysis for vehicle attributes.
• Troubleshoot prototype and production processes, collaborating with part leads to resolve issues, using simulation as a key tool.
• Maintain design records and documentation, including simulation reports and validation data.