Sr. Manufacturing Controls Dev Engineer, Simulations, Castings

The Castings Manufacturing Engineering Group is the part of the Materials Engineering Group responsible for the design, build, launch and handover of state of the art Casting lines and equipment currently used for vehicle and humanoid programs. This team is focusing on achieving the highest efficiency, manufacturing volume and safety while proving performance and documenting every aspect of the project for handover to sustaining.

The Manufacturing Controls Development Engineer in Castings will lead simulation-driven design, virtual commissioning, and digital twin development for high-volume automation systems, including Tesla's Giga Press die casting lines. You'll bridge the gap between digital models and real-world execution by leveraging Process Simulate, robotics simulation, and PLC synchronization to validate designs before deployment.

• Develop high-fidelity 3D simulations of robotic work cells and full automation lines using Siemens Process Simulate, ensuring accurate geometry, kinematics, and tooling integration from Siemens NX/Teamcenter
• Program and validate Fanuc (KUKA/ABB preferred) robot paths offline, optimizing cycle times, collision avoidance, and reach studies in Process Simulate
• Synchronize simulated robot logic with TIA Portal/PLCSIM to validate control sequences, I/O signals, and safety systems before physical commissioning
• Collaborate with mechanical, electrical, and controls teams to ensure simulated logic matches real-world PLC behavior and develop the logic models where needed
• Use simulation data to refine layouts, ergonomics, and automation strategies, balancing process requirements with cost and lead-time constraints
• Generate simulation reports, validation videos, and digital twin documentation for stakeholder reviews and engineering signoffs
• Drive adoption of virtual commissioning workflows to reduce physical prototyping costs and accelerate equipment ramp to start production
• Degree Controls Engineering, Mechatronics Engineering, Electrical Engineering, or equivalent experience
• Advanced skills in Siemens NX (basic assembly/navigation) and Teamcenter for data management/version control
• Expertise in Fanuc robot simulation (KUKA/ABB a plus), including path planning, TP code, and offline programming
• Strong understanding of PLC logic (Siemens TIA Portal preferred), ladder logic, and safety controllers in a simulated environment
• Hands-on experience with virtual I/O synchronization using tools like PLCSIM or SIMIT to validate control systems digitally
• Strong problem-solving skills with a focus on first-principles analysis for virtual validation and root cause troubleshooting
• Familiarity with safety standards (ANSI/RIA15.06, ISO 13849) in digital twin workflows
• Experience with tools for virtual commissioning (iPhsyics, Tecnomatix Process Simulate, WinMOD, MapleSim, Emulate3D, EKS, etc.) preferred
• Experience with CAD software (SolidWorks, AutoCAD) or scripting (Python, VBA) for simulation automation preferred