Senior Materials Engineer (Metals, Forming & Castings)

Senior Materials Engineer (Metals, Forming & Castings)

Foster City, CA

Vehicle Development - Vehicle Integration Engineering /

Full-time /

On-site

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We are seeking a Senior Materials Engineer to lead failure analysis, metallurgical investigation, and root-cause corrective action for our Materials & Failure Analysis team. This is a senior, independent contributor role for someone who owns investigations end-to-end; from initial part triage through mechanical testing, metallurgical analysis, and cross-functional resolution with Design, Manufacturing, and Supplier Quality. The ideal candidate has deep expertise across metals and metal manufacturing processes; forming, stamping, and castings, and is comfortable authoring the specifications that govern them, working at the microscope, running mechanical tests in the lab, and presenting findings to program leadership.

In this role, you will:

• Lead failure investigations for metallic components across development, production, and field releases; execute mechanical testing and metallurgical characterization (SEM/EDS, metallography, fractography) to determine root cause and mitigations.

• Advise Design, Manufacturing, and Quality teams on metal selection, process capability, and process-induced failure modes for forming, stamping, and casting operations (DFMEA/PFMEA).

• Draft and maintain material and process specifications, quality acceptance criteria, and ASTM/ISO/SAE test procedures.

• Support supplier material and process qualification for formed, stamped, and cast metal components, including review of PPAP submissions and material certifications.

• Manage lab test plans, equipment calibration, SOPs, and safety standards while directing external vendor labs and mentoring junior engineers.

Qualifications

• Bachelor's or Master's degree in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering, or a related field.

• 8+ years of experience in materials engineering, failure analysis, or metallurgical engineering, ideally in automotive, aerospace, or heavy equipment.

• Deep, hands-on expertise with metals across forming/stamping and casting processes, and their common failure modesDeep, hands-on expertise with metals across forming/stamping and casting processes, and their common failure modes as well as writing and reviewing processes.

• Strong experience with mechanical testing (Instron/UTM systems) and failure analysis techniques (fractography, SEM/EDS, metallography, hardness testing).

• Demonstrated track record independently leading root cause investigations and driving corrective actions to closure with cross-functional teams.

• Working knowledge of ASTM/ISO/SAE test standards and experience developing test specifications.

• Excellent written and verbal communication skills, with the ability to translate technical findings for non-materials audiences and leadership.

• Experience mentoring or directing the work of junior engineers or technicians.

Bonus Qualifications

• Experience with polymers, composites, adhesives/bonded joints, or coatings failure analysis.

• Familiarity with forming/stamping simulation tools (e.g., AutoForm, LS-DYNA), casting simulation, or DFMEA/PFMEA processes.

• Experience with supplier quality engineering, PPAP, or material certification review.

• Prior experience in high-volume automotive manufacturing or a vehicle development environment.

• Advanced degree (MS/PhD) in Materials Science or Metallurgy.

$187,000 - $225,000 a year

Base Salary Range

There are three major components to compensation for this position: salary, Amazon Restricted Stock Units (RSUs), and Zoox Stock Appreciation Rights. A sign-on bonus may be offered as part of the compensation package. The listed range applies only to the base salary. Compensation will vary based on geographic location and level. Leveling, as well as positioning within a level, is determined by a range of factors, including, but not limited to, a candidate's relevant years of experience, domain knowledge, and interview performance. The salary range listed in this posting is representative of the range of levels Zoox is considering for this position.

Zoox also offers a comprehensive package of benefits, including paid time off (e.g. sick leave, vacation, bereavement), unpaid time off, Zoox Stock Appreciation Rights, Amazon RSUs, health insurance, long-term care insurance, long-term and short-term disability insurance, and life insurance.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.

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