Sr. Foundry Process Engineer

About the role

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.

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

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