Senior Tooling Engineer

What we offer:

At Magna, you can expect an engaging and dynamic environment where you can help to develop industry-leading automotive technologies. We invest in our employees, providing them with the support and resources they need to succeed. As a member of our global team, you can expect exciting, varied responsibilities as well as a wide range of development prospects. Because we believe that your career path should be as unique as you are.

Group Summary:

Cosma provides a comprehensive range of body, chassis and engineering solutions to global customers. Through our robust product engineering, outstanding tooling capabilities and diverse process expertise, we continue to bring lightweight and innovative products to market.

Job Responsibilities:

• Design and optimize high-pressure die casting tooling, including gating, runner, cooling, vacuum, sealing, and trim systems to achieve superior product quality, productivity, and casting yield.
• Develop die seal concepts and vacuum system solutions to maximize vacuum performance and minimize leakage.
• Design and validate cooling systems to ensure thermal balance, dimensional stability, optimal cycle times, and consistent casting quality.
• Drive tooling and process improvements across global casting operations, including hydraulic cores/slides, squeeze cores, jet-cooled cores, vacuum systems, and related technologies.
• Provide technical expertise to improve tooling performance through optimized materials, coatings, and tooling practices that extend die life and reduce soldering.
• Establish, maintain, and deploy global die and tooling standards to improve production efficiency, casting yield, quality, and cost competitiveness.
• Analyze thermal imaging, casting data, and tooling performance to identify opportunities for process and tooling optimization.
• Conduct dimensional capability studies and implement corrective actions to improve product quality and process capability.
• Apply proactive engineering methodologies, including FMEA, risk assessment, and lessons learned, to ensure successful program launches and first-time-pass objectives.
• Utilize Design for Manufacturability (DFM) principles to assess product feasibility, tooling concepts, and manufacturing readiness.
• Collaborate with simulation and manufacturing teams to correlate simulation results with production trials and optimize casting performance.
• Lead standardization of GD&T interpretation and casting tolerance requirements for structural die-cast components.
• Partner with global tooling suppliers to evaluate tooling concepts, costs, lead times, and technical feasibility.
• Develop and implement engineering tools, calculations, CAD standards, and automation solutions to improve design efficiency and reduce engineering lead times.
• Support customer discussions to finalize product designs, technical specifications, and manufacturing requirements while meeting quality, cost, delivery, and productivity targets.
• Maintain and improve CAD data management systems for products, tooling, fixtures, and manufacturing equipment.
• Capture, document, and share best practices and lessons learned across global casting operations.
• Provide technical support and troubleshooting expertise for casting processes, tooling, downstream manufacturing processes, and value engineering initiatives.
• Support new product and process development activities focused on performance improvement and cost reduction.

Qualification requirements

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Metallurgical Engineering, or a related field.
• Several years of experience in High Pressure Die Casting (HPDC), preferably within the automotive industry.
• Demonstrated experience in die design, gating systems, runner design, cooling system design, and tooling development.
• Strong understanding of HPDC process fundamentals, tooling design principles, and casting defect prevention.
• Proven ability to assess manufacturing feasibility from component drawings, specifications, and assemblies.
• Proficiency in 2D and 3D CAD software, including AutoCAD, Siemens NX, and Spinfire.
• Working knowledge of casting simulation software such as MAGMASoft and/or Flow-3D (preferred).
• Strong understanding of Geometric Dimensioning & Tolerancing (GD&T).
• Experience with Design for Manufacturability (DFM), Value Engineering (VE), and continuous improvement methodologies.
• Knowledge of Failure Mode and Effects Analysis (DFMEA, PFMEA) and risk-based engineering approaches.
• Strong problem-solving, analytical, and root-cause investigation skills.
• Hands‑on experience in manufacturing support, process optimization, an