Technical Manager- Advanced High Pressure Die Casting (HPDC)

PSW Group•Chicago, IL

1d•$100,000 - $150,000

About The Position

PSW Group is a leading magnesium and aluminum manufacturer advancing nonferrous metal technologies. We are investing in an state-of-the-art Advanced Casting Technology Development Center which will increase new HPVDC, semi-solid casting, and other new 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. We are seeking an experienced Technical Manager with hands on experience on HPDC to lead technology development, pilot programs, and customer collaborations that strengthen PSW’s technical leadership and market presence. The salary range will be $100-150k base pay + performance bonuses depending on level of experience.

Requirements

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.

Nice To Haves

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.

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.