Sr. Foundry Process Engineer

What to Expect

Own the design, definition, implementation, and long-term sustainment of Melt Center processes that deliver consistent, high-quality molten aluminum to Tesla’s high-pressure die casting (HPDC) operations. Act as the technical authority for melting, holding, cleaning, and metal transfer — and providing clear process and design inputs for future melting, holding, and transfer systems.

What You'll Do

• Define furnace cleaning, fluxing, and metal-treatment practices that maximize melt quality, recover metal from dross, and extend refractory life, while leading adoption of new metal-cleaning concepts across the melt path
• Establish process requirements and operating standards for scrap loading, melting rate, holding practice, and quality gates before transfer to HPDC machines
• Collaborate with cross-functional teams to lock requirements (melt rate, transfer rate, cleaning frequency, loading cadence) for new and existing melting and transfer systems
• Drive functional requirements for metal transfer systems (pumps, auto-tappers, launders, ladles) and partner with stakeholders and OEMs so design-phase solutions meet operational, quality, and reliability needs
• Commission and troubleshoot new Melt Center equipment, verifying performance against melt rate, transfer rate, refractory life, and metal-quality targets
• Lead sustaining and continuous-improvement projects with Operations, Facilities, and Maintenance, with a primary focus on operational safety
• Translate process learnings into design inputs for next-generation melting, holding, and transfer systems

What You'll Bring

• Degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, or equivalent combination of education and experience
• 10+ years in secondary aluminum foundry / melting operations (casthouse or melt center strongly preferred)
• Proven experience introducing new foundry equipment and processes into live production, with project management from concept through commissioning and sustainment
• Hands-on expertise across refractory systems and repairs, scrap loading, melting process control, metal cleaning/treatment, launder and ladle transfer, and dross processing
• Experience defining process workflows and driving floor-level implementation with Operations, Facilities, and Maintenance to solve problems and implement long-term solutions
• Experience designing manufacturing layouts and equipment interfaces in 2D (AutoCAD) and/or 3D (CATIA / SolidWorks)
• Strong written and verbal communication skills with technical and non-technical audiences

Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Medical plans > plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company paid Basic Life, AD&D
• Short-term and long-term disability insurance (90 day waiting period)
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
• Back-up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight Loss and Tobacco Cessation Programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program

Tesla is an Equal Opportunity / Affirmative Action employer committed to diversity in the workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, age, national origin, disability, protected veteran status, gender identity or any other factor protected by applicable federal, state or local laws.

Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities. Please let your recruiter know if you need an accommodation at any point during the interview process.