Arch Casting Simulation Engineer

Job Description

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we're all a part of something bigger than ourselves. Are you ready to change the way the world moves?

Ford's Electric Vehicles, Digital and Design (EVDD) team is charged with delivering the company's vision of a fully electric transportation future. EVDD is customer-obsessed, entrepreneurial, and data-driven and is dedicated to delivering industry-leading customer experience for electric vehicle buyers and owners. You'll join an agile team of doers pioneering our EV future by working collaboratively, staying focused on only what matters, and delivering excellence day in and day out. Join us to make positive change by helping build a better world where every person is free to move and pursue their dreams.

Responsibilities

What you'll do...

• Develop and implement casting simulation strategies for future EV platforms, collaborating with part leads from concept to mass production.

• Set up and optimize flow and solidification analysis using Magmasoft and Flow3d to predict and improve casting quality.

• Integrate flow analysis results with 3D casting designs, balancing construction, material selection, and manufacturing methods. Collaborate with part leads to ensure part design considerations are fully integrated, addressing die life, cooling, material flow, and part distortion.

• Utilize simulation tools to predict casting defects, optimize casting process including shot profile, cycle time, optimize cooling, minimize part distortion, and ensure part manufacturability.

• Optimize casting and part designs using analytical assessments, maximizing die life, minimizing cycle times, and improving part quality through continuous feedback between casting and part design.

• Develop and implement advanced casting technologies (e.g., gating systems, die cooling, spray, extraction, and quench strategies) based on simulation results. Collaborate with material scientists for optimal material selection.

• Optimize alloys to enhance die life and part performance, collaborating with part leads for optimal material choices, informed by simulation data.

• Develop and use predictive models to maximize die life, considering part design impacts and simulation results.

• Integrate and apply AI/machine learning for data-driven optimization of the casting process, addressing quality issues, part distortion, and OEE. Use this data to inform both casting and part design and die life improvements.

• Participate in design reviews, presenting casting simulation results, integrated casting and part design concepts, and recommendations.

• Work cross-functionally to overcome technical challenges related to casting.

• Develop tools and methods for faster casting and part development, feeding CAE analysis for vehicle attributes.

• Troubleshoot prototype and production processes, collaborating with part leads to resolve issues, using simulation as a key tool.

• Maintain design records and documentation, including simulation reports and validation data.

Qualifications

You'll have...

• BS/MS in Mechanical Engineering, Materials Science, or related field; 5+ years' experience in high-volume casting simulation (automotive preferred).

• 3+ years' experience with 3D CAD software (collaborative experience).

• Strong understanding of casting processes, materials, and techniques.

• Expertise in setting up and optimizing flow analysis using Magmasoft and Flow3d.

• Strong analytical skills and experience with CAE tools (casting simulation).

• Experience with alloy selection and casting process parameters.

• Experience with AI/machine learning in manufacturing (a plus).

• Systems approach to design and development; commitment to continuous improvement.

• Experience with GD&T and relevant industry standards.

• Strong analytical/problem-solving skills; detail-oriented and highly motivated.

• Excellent communication and collaboration skills.

You may not check every box, or your experience may look a little different from what we've outlined, but if you think you can bring value to Ford Motor Company, we encourage you to apply

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a change maker, a technical expert, a culture builder...or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, and prescription drug coverage

• Flexible family care, parental leave, new parent ramp-up programs, subsidized back-up child care and more

• Vehicle discount program for employees and family members, and management leases

• Tuition assistance

• Established and active employee resource groups

• Paid time off for individual and team community service

• A generous schedule of paid holidays, including the week between Christmas and New Year's Day

• Paid time off and the option to purchase additional vacation time.

For a detailed look at our benefits, click here: https://corporate.ford.com/content/dam/corporate/us/en-us/documents/careers/2024-benefits-and-comp-GSR-sal-plan-2.pdf

Visa sponsorship is available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer committed to a culturally diverse workforce. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.