Job Description

Mechanical Design Engineer - Metal (Tooling & Surface Engineering)

Position Overview

The Mechanical Design Engineer - Metal is responsible for the design, development, and optimization of metal forming tools, molds, and surface treatment processes. This role supports die casting, metal stamping, and plating operations to ensure high-quality, cost-effective, and manufacturable products.

The position works closely with cross-functional teams including production, tooling, quality, and R&D to drive product and process improvements, troubleshoot technical issues, and support new product development.

Key Responsibilities

1. Tooling & Mold Design (Stamping and Die Casting)

Design and develop press stamping dies (progressive, transfer, compound, single-hit) and die cast molds.
Create detailed 3D models, assemblies, and 2D drawings using CAD software.
Define layouts, material flow, gating systems, cooling channels, and ejection systems.
Ensure designs meet product specifications, tolerances, and manufacturability requirements.

2. Engineering Analysis & Process Validation

Perform design for manufacturability (DFM) and feasibility studies.
Analyze metal forming and casting behavior (e.g., flow, shrinkage, springback, porosity).
Support simulation activities where applicable.
Identify risks and recommend technical solutions for defects and inefficiencies.

3. Plating & Surface Engineering (SME Scope)

Provide technical expertise in metal plating processes (e.g., electroplating, surface finishing).
Ensure proper coating specifications, adhesion, corrosion resistance, and surface quality.
Support troubleshooting of plating defects such as peeling, uneven coating, discoloration, or contamination.
Collaborate with suppliers and production teams to optimize plating processes and compliance.

4. Support to Manufacturing & Tool Build

Work with toolmakers, machinists, and production teams during fabrication and assembly.
Provide technical guidance during tooling build, machining, and mold/die trials.
Ensure design intent is maintained through manufacturing stages.
Support first article runs, trials, and production ramp-up.

5. Troubleshooting & Continuous Improvement

Diagnose tooling, mold, or plating-related issues and implement corrective actions.
Optimize designs for reduced scrap, improved cycle time, and longer tool life.
Recommend improvements in materials, processes, and design standards.
Drive cost reduction and efficiency initiatives.

6. Documentation & Compliance

Prepare and maintain engineering drawings, BOMs, and technical documentation.
Ensure compliance with company standards, safety requirements, and customer specifications.
Support quality systems such as PPAP, APQP, and engineering change processes.
Maintain accurate revision control and documentation records.

7. Cross-Functional Collaboration

Coordinate with R&D, production, quality, and maintenance teams.
Interface with suppliers, tooling vendors, and external partners.
Participate in design reviews, project meetings, and technical discussions.
Provide updates on project status and technical performance.

Qualifications

Education

Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, or related field
Tool & Die or surface engineering certifications are an advantage

Experience

Minimum 2-5 years in any of the following:
- Tooling or die design (stamping or die casting)
- Mold design or metal forming processes
- Plating or surface treatment engineering
Experience in high-volume manufacturing is preferred

Technical Skills

Proficiency in CAD software (e.g., SolidWorks, CATIA, NX, AutoCAD)
Strong knowledge of:
- Metal stamping and die design
- Die casting processes and mold design
- Plating and surface finishing processes
Understanding of GD&T, engineering drawings, and tolerances
Familiarity with simulation tools is a plus
Knowledge of materials (steel, brass, aluminum, zinc, etc.)

Core Competencies

Strong analytical and problem-solving skills
Attention to detail and technical accuracy
Ability to manage multiple projects and deadlines
Effective communication and teamwork
Continuous improvement mindset
Strong documentation and reporting skills

Key Performance Indicators (KPIs)

Design quality and first-pass approval rate
Reduction in defects (tooling, casting, plating)
On-time project delivery
Cost savings and efficiency improvements
Tool/mold performance and reliability
Cross-functional feedback

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Mechanical Design Engineer - Metal

Welder