Senior Die Casting Process Engineer, Amazon Industrial Robotics

Amazon Industrial Robotics is seeking exceptional talent to help bridge the gap between design and manufacturing for our next generation of advanced robotics systems. We're building revolutionary manufacturing processes that enable the production of cutting-edge robotic systems at Amazon's scale.

In this role, you will serve as our die casting process expert, partnering directly with die cast suppliers and tooling shops to achieve audacious production goals for complex robotic components. You'll lead process development initiatives, working hands-on to optimize die casting parameters, tooling design, and quality systems while simultaneously contributing to the design of our future high-volume manufacturing facility. This is a unique opportunity to pioneer advanced die casting techniques at an unprecedented scale, bridging immediate production needs with long-term factory design, working with world-class teams to build the production systems that will bring next-generation robotics to life. If you're passionate about pushing the boundaries of die casting technology and creating manufacturing processes of tomorrow rather than just optimizing those of today, this role offers the chance to make a lasting impact on the future of automation.


Key job responsibilities
- Lead die casting process development and optimization in partnership with external suppliers and die tooling shops to meet quick production targets
- Collaborate with die tooling designers to develop and refine tooling concepts, gating systems, and cooling strategies for complex robotic components
- Provide design for manufacturing feedback to hardware engineering teams to optimize part designs for die castability, quality, and cost
- Establish process parameters, quality control methods, and inspection criteria for high-integrity die cast components
- Troubleshoot and resolve die casting defects including porosity, shrinkage, flash, and dimensional issues in production environments
- Develop supplier quality systems and work instructions to ensure consistent part quality and process capability
- Contribute to the design and layout of our future high-volume die casting facility, including equipment selection, process flow, and automation concepts
- Create flexible manufacturing concepts that support product design iteration while maintaining production efficiency
- Generate comprehensive process documentation, PFMEA, control plans, and manufacturing specifications
- Work with cross-functional teams including design engineering, quality, and supply chain to ensure smooth production ramp-up and long-term scalability

Basic Qualifications

- Experience collaborating and influencing multiple teams across multiple organizations
- Bachelor's degree in Mechanical Engineering, Materials Science, Manufacturing Engineering, or related engineering field
- 5+ years of hands-on experience in die casting process engineering in high-volume production environments (automotive, aerospace, consumer electronics, or similar industries)
- Deep expertise in die casting fundamentals including alloy selection, gating design, thermal management, and defect mitigation
- Experience working directly with die casting suppliers and tooling shops to develop and optimize production processes
- Knowledge of CAD software (SolidWorks or similar) and ability to review part designs for die castability
- Experience with die casting simulation software (e.g., MAGMA, Flow-3D, ProCAST, or similar)
- Proven track record troubleshooting complex die casting quality issues and implementing corrective actions
- Experience writing technical documentation including process specifications, work instructions, and quality control plans
- Strong understanding of GD&T, inspection methods, and statistical process control

Preferred Qualifications

- Master's degree in mechanical engineering, electrical engineering, material science, physics or equivalent, or MS degree
- 8+ years of die casting process engineering experience in automotive or aerospace industries
- Experience with high-pressure die casting (HPDC) of aluminum and magnesium alloys for structural applications
- Expertise in advanced die casting techniques such as vacuum-assisted casting, squeeze casting, or semi-solid casting
- Experience designing or specifying die casting equipment and automation systems
- Background in factory layout, equipment selection, and manufacturing facility design
- Experience with Lean Manufacturing principles and continuous improvement methodologies
- Knowledge of secondary operations including machining, surface treatment, and assembly of die cast components
- Experience taking products from prototype through high-volume production launch
- Familiarity with robotic systems, electro-mechanical assemblies, or complex mechanical products

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