Tooling & Die Design Engineer – HPDC

Core Responsibilities

• Tooling Design & Simulation Engineering
• Advanced Simulation: Utilize MAGMA5, FLOW-3D, or equivalent liquid flow modeling tools to perform comprehensive 3D flow, thermal, and solidification simulations.
• Die & Gating Design: Design and optimize complete die casting tooling layouts, including gating systems, runners, overflows, venting, and thermal management (cooling/heating) channels.
• Design for Manufacturing (DFM): Lead detailed DFM reviews, translating simulation results into concrete engineering recommendations for wall thicknesses, draft angles, fillets, and parting lines.
• Troubleshooting & Optimization: Analyze production tooling wear or casting defects and engineer permanent design modifications to improve die life and quality yields.
• OEM Customer Interface & Collaboration
• On-Site Technical Liaison: Embed with OEM customer engineering teams at their sites during early development phases to provide face-to-face technical support and build strong, trusting partnerships.
• Cross-Functional Communication: Translate complex fluid dynamics and metallurgical data into clear, actionable design feedback for both highly technical internal teams and external client stakeholders.
• NPI Support: Actively participate in prototype builds and early New Product Introduction (NPI) phases to ensure client expectations align perfectly with production realities.
• Documentation: Develop and maintain rigorous documentation for design changes, simulation logs, control plans, and customer design sign-offs.

Qualifications

• Experience: 3 to 5 years of dedicated experience in tooling design and simulation engineering specifically for aluminum and/or magnesium high-pressure die casting.
• Education: Bachelor’s degree in Mechanical Engineering, Metallurgical Engineering, Materials Science, or a related engineering discipline.
• Simulation Expertise: Proven proficiency running advanced 3D liquid flow and solidification modeling software (e.g., MAGMA, FLOW-3D).
• CAD Proficiency: Strong hands-on experience with 3D CAD design software (such as NX, Catia, or Creo).

Preferred qualifications

• 3 to 5 years of hands-on experience working directly in the HPDC industry or within an Automotive OEM’s product development team.
• Superior Communication: Excellent verbal and written communication skills in English, with the polished presence necessary to represent PSW Group directly on-site at major OEM facilities.
• Problem Solving & Adaptability: Excellent organizational skills, attention to detail, and the flexibility to balance shifting customer requirements with internal production capabilities.

Work Environment

• Primarily office-based with regular travel to manufacturing sites, supplier locations, and industry events.
• Occasional extended hours may be required to meet project deadlines and business needs.
• Frequently required to sit.

Comp & Benefits

• A competitive salary, discretionary bonus, the ability to participate in a 401k plan with a company match, medical, dental, vision, life, disability and other types of group and individual coverages.

About PSW Group

• PSW Group is a leading recycler and producer of non-ferrous lightweight metals, specializing in magnesium and aluminum.
• We supply a broad range of products including secondary magnesium alloys, primary and secondary aluminum alloys, and tolling and chip recycling services.
• Our international production facilities in North America, Europe, and Asia provide us with a cross-continental network of reliable supply that is unrivaled in the industry.
• We stand at the forefront of sustainability by investing in technologies and processes to reduce our carbon footprint while maintaining the highest quality of our products.
• We are committed to providing the highest quality raw materials to build your unique products and realize your most innovative ideas.
• We strive to provide consistent, superior, and sustainable lightweight solutions to meet and exceed our customers' needs.