Transmission and Driveline Housings and Castings Design Specialist

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.

Basic Qualifications:

• Bachelor's degree in Mechanical Engineering, Materials Science, or related degree field
• 10 or more years of industry experience with a focus on aluminum high pressure die casting for automotive powertrain applications
• Extensive experience with sealing solutions for aluminum castings, including gasketed joints, edge-bonded seals, and RTV applications; skilled in optimizing surface flatness, finish, bolt patterns, and managing thermal distortion for robust leak-free performance
• Strong expertise in fastened joint design for cast structures, including thread engagement, insert integration, torque retention, and joint durability under thermal and mechanical loading conditions
• Ability to interpret results for both structural and thermal performance
• Familiarity with casting simulation tools such as MAGMASOFT or ProCAST
• Experience in tooling development, including die construction, cooling system layout, and die maintenance considerations
• Proven success in launching HPDC components into mass production, with clear contributions from concept to production validation
• Excellent problem-solving skills, especially related to casting defects, sealing issues, and fastener retention problems
• Effective communicator with ability to work across engineering, quality, manufacturing, and supplier teams

Preferred Qualifications:

• Master's degree in Mechanical Engineering
• Knowledge of APQP, PPAP, and casting supplier qualification processes
• Experience in lightweighting strategies for cast aluminum powertrain systems
• Exposure to joint-level testing, torque audits, and NVH considerations in cast assemblies