We are seeking a highly experienced and technically proficient Transmission and Driveline Housings and Castings Design Specialist to join our Powertrain Engineering team. The ideal candidate will bring deep expertise in high pressure die casting (HPDC) for automotive powertrain components, with a strong foundation in casting process development, structural simulation, sealing and fastening strategies, and tooling optimization.
This position will lead the development of aluminum castings from concept through launch, ensuring robust, defect-free, and production-ready designs that meet structural and functional requirements.
Key Responsibilities:
- Lead the design and development of HPDC aluminum cast components such as transmission housings, transfer case adaptors, and gearbox covers, focusing on function, durability, and manufacturability.
- Develop clean-sheet designs and optimize existing components for performance, manufacturability, and cost.
- Lead structural FEA (Finite Element Analysis) to validate casting performance, and interpret stress, strain, and fatigue results to inform design optimization.
- Iterate design geometry, wall thickness, ribbing, and local features to improve strength, reduce mass, and eliminate failure modes based on FEA insights.
- Collaborate on sealing surface development, including flatness, surface finish, thermal distortion prediction, and compatibility with gaskets and sealants.
- Provide technical guidance on fastener integration, including thread design, boss geometry, torque retention, pull-out strength, and clamp load analysis in cast aluminum substrates.
- Review and optimize tooling design and die construction, including thermal control, die wear, and casting cycle time efficiency.
- Lead root cause investigations for casting-related issues such as porosity, dimensional variation, soldering, and surface defects using tools like CT scans, microscopy, and statistical analysis.
- Support supplier engagement and qualification, ensuring alignment of casting quality and process capability with design intent.
- Document and share best practices in aluminum casting, sealing, and fastening as part of internal technical standards and design guides.
- Mentor junior engineers and provide technical leadership across product and manufacturing teams.