Unicasting Casting Process Engineer


On Site
Full Time


Program management
Process engineering
Product development
Manufacturing engineering
Design review
Risk management
Electrical engineering
Mechanical engineering
Materials science
Problem solving
Process control
Automotive Manufacturing
Marketing intelligence
Value engineering

Job Details

Job Description

In this role, the Unicasting Casting Process Engineer will define and deliver next-generation Unicasting manufacturing processes in support of future-model vehicle programs. Successful candidates will have a proven record of working with cross functional teams in the development and implementation of processes for structural aluminum high pressure die castings.

The Unicasting Casting Process Engineer will be responsible for defining and implementing the casting process, from early program planning through facility launch. In this role, the engineer will have direct-line impact over the process development, bill of process and equipment identification and integration of Unicastings. This process is a new to Ford manufacturing process and must combine both technical and leadership capabilities to drive success. Ideal candidates must navigate and drive change in a complex internal environment, challenging the status quo as we define an all-new way of manufacturing vehicles.

  • Work within a cross-functional manufacturing team towards development and execution of Unicasting manufacturing from early concept through facility launch.
  • Advanced knowledge of casting manufacturing processes with hands-on experience.
  • Leverage expertise from internal and external workgroups to drive strategy, resolve challenges, and deliver results.
  • Utilize knowledge of quality processes and systems to meet stringent industry and customer requirements.
  • Drive "Voice of Manufacturing" throughout product development lifecycle to ensure robust, feasible, and manufacturable casting assembly designs.
  • Define and launch formal equipment and process standards for high pressure die cast tooling, casting equipment and post-processing cells.
  • Lead scope-of-work development and competitive bidding exercises for Unicasting manufacturing systems.
  • Drive continuous benchmarking of best-in-world practices for HPDC applications and utilize findings to improve Ford strategy.
  • Work within a manufacturing engineering team to execute tooling design reviews, risk mitigation, commissioning processes, and launch handoff with a Ford manufacturing facility.
  • Deliver on-time and on-budget launch for upcoming Unicasting programs.

Minimum Qualifications
  • Bachelor of Science/Engineering; MBA/MS preferred - Chemical/Electrical/Mechanical or Metallurgy/Materials Science.
  • 5+ years prior experience with high pressure die casting, preferably for structural applications.

Preferred Qualifications
  • Strong communication skills, both written and oral.
  • Working level knowledge of high pressure die casting, post processing, and die development processes.
  • Knowledge of alloys used for structural castings, furnace/melting operations and metal quality.
  • Knowledge of the different die spray processes and different lubricant types used. Candidate should have practical experience with setting and manipulation of die spray nozzles and set-up of spray process.
  • Experience with the development of a shot curve and development of a process for a new casting.
  • Understanding of MagmaSoft or other casting simulation software results.
  • Excellent problem-solving skills and the ability to make decisions in a fast paced, dynamic environment.
  • Exceptional communication and interpersonal skills to present, persuade, and collaborate at all levels of the organization.
  • Highly motivated self-starter capable of driving change and influencing engineering decisions, with or without authority.
  • Experience performing casting manufacturing feasibility assessments.
  • Foundry operational experience in casting manufacturing processes and process control.
  • Proven track record of delivering major product launches in an automotive manufacturing facility.
  • The ability to travel daily to Livonia, MI for the remainder of '24 and 50% in Lousiville, KY (targeting by June '25).

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!

What you'll receive in return:

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 changemaker, 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:

Please see our Company Profile.

Visa sponsorship is available for this position.

Relocation assistance 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-.


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