Senior Tooling Engineer

Magna International • Troy, MI

2d

About The Position

The Senior Tooling Engineer designs, develops, and optimizes high-pressure die casting (HPDC) tooling and related systems to improve product quality, productivity, casting yield, and cost competitiveness. The role supports global casting operations and works across tooling design, manufacturing, simulation, suppliers, and customers. It also contributes to new product and process development, tooling standards, and continuous improvement initiatives.

The position covers tooling systems including gating, runners, cooling, vacuum, sealing, trim systems, hydraulic and squeeze cores, and jet-cooled cores. The engineer analyzes tooling and casting performance, thermal imaging, and dimensional capability; applies DFM, FMEA, risk assessment, and lessons learned; and supports program launches, production troubleshooting, and process optimization. The role also develops engineering tools, calculations, CAD standards, and automation, maintains CAD data management systems, and shares best practices across global operations.

The work environment includes both office and manufacturing plant settings, with collaboration across Cosma Casting operations in Europe and North America. International travel may be required. This is a regular, permanent position.

Requirements

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Metallurgical Engineering, or a related field.
• Several years of experience in High Pressure Die Casting (HPDC), preferably within the automotive industry.
• Demonstrated experience in die design, gating systems, runner design, cooling system design, and tooling development.
• Strong understanding of HPDC process fundamentals, tooling design principles, and casting defect prevention.
• Ability to assess manufacturing feasibility from component drawings, specifications, and assemblies.
• Proficiency in 2D and 3D CAD software, including AutoCAD, Siemens NX, and Spinfire.
• Strong understanding of Geometric Dimensioning & Tolerancing (GD&T).
• Experience with Design for Manufacturability (DFM), Value Engineering (VE), and continuous improvement methodologies.
• Knowledge of Failure Mode and Effects Analysis (DFMEA, PFMEA) and risk-based engineering approaches.
• Strong problem-solving, analytical, and root-cause investigation skills.
• Hands-on experience in manufacturing support, process optimization, and troubleshooting.
• Excellent communication skills and ability to collaborate effectively across global teams.
• Professional proficiency in English.
• Willingness and ability to travel internationally as required.

Nice To Haves

• Working knowledge of casting simulation software such as MAGMASoft and/or Flow-3D.
• HPDC experience within the automotive industry.

Responsibilities

• Design and optimize high-pressure die casting tooling, including gating, runner, cooling, vacuum, sealing, and trim systems.
• Develop die seal concepts and vacuum system solutions to improve vacuum performance and minimize leakage.
• Design and validate cooling systems for thermal balance, dimensional stability, cycle time, and casting quality.
• Drive tooling and process improvements across global casting operations, including hydraulic cores/slides, squeeze cores, jet-cooled cores, and vacuum systems.
• Improve tooling performance through optimized materials, coatings, and tooling practices that extend die life and reduce soldering.
• Establish, maintain, and deploy global die and tooling standards.
• Analyze thermal imaging, casting data, and tooling performance to identify optimization opportunities.
• Conduct dimensional capability studies and implement corrective actions.
• Apply FMEA, risk assessment, and lessons learned to support successful program launches and first-time-pass objectives.
• Use DFM principles to assess product feasibility, tooling concepts, and manufacturing readiness.
• Collaborate with simulation and manufacturing teams to correlate simulation results with production trials and optimize casting performance.
• Lead standardization of GD&T interpretation and casting tolerance requirements for structural die-cast components.
• Partner with global tooling suppliers to evaluate tooling concepts, costs, lead times, and technical feasibility.
• Develop engineering tools, calculations, CAD standards, and automation to improve design efficiency and reduce engineering lead times.
• Support customer discussions to finalize product designs, technical specifications, and manufacturing requirements while meeting quality, cost, delivery, and productivity targets.
• Maintain and improve CAD data management systems for products, tooling, fixtures, and manufacturing equipment.
• Capture, document, and share best practices and lessons learned across global casting operations.
• Provide technical support and troubleshooting for casting processes, tooling, downstream manufacturing processes, and value engineering initiatives.
• Support new product and process development focused on performance improvement and cost reduction.
• Travel internationally as required.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior