Experienced simulation engineer / Process Engineer at Voit Automotive GmbH (2022-02 – Present)
- Lead and provide technical guidance to a team of five employees
- Implemented process optimization measures such as analysis, evaluation and improvement of existing die casting processes with a focus on quality, scrap reduction, cycle time reduction and process stability
- Reduced leakage rate of a product from approx. 25% to 2.5% within five months
- Shortened the cycle time of several products by 10s or more while maintaining quality
- Executed continuous improvement (CIP) measures, increasing mold lifetime by 20,000 cycles
- Planned, executed, and evaluated casting simulations using Magma software for optimization of filling and solidification, including temperature and stress simulations
- Derived and implemented technical measures from simulation results in collaboration with design, toolmaking, quality assurance, and production departments
- Adjusted casting concepts to reduce defects (pores, shrinkage, presolidification, delamination, etc.)
- Contributed to feasibility studies for new customer inquiries (casting concepts)
- Delivered technical presentations to customers
- Participated in investment projects, particularly analyzing semisolid processes (Rheocasting, Meltec) and 3D tempering channels (conformal cooling)
- Supervised research and development topics
- Managed and optimized manufacturing process using AI-based analysis tool, gaining hands-on experience in data-driven process optimization and automated decision support
- In-depth experience with pressure-tight components (helium and air testing) as well as laser and Friction Stir weldable casting using full-vacuum die casting molds
- Broad experience with product portfolios including gearbox components (intermediate plates 8HP), Battery housings, Airconditioning compressors, and more
Simulation Engineer and Technical Project Management at BOHAI-Trimet Automotive Holding GmbH (2013-05 – 2022-01)
- Conducted and evaluated mold-filling and solidification simulations as well as thermal cycle and stress calculations
- Optimized parameters and validated simulation results
- Presented on the topic "Optimization of a Shrinkage Cavity using Squeezer" at the Flow 3D User Meeting
- Managed research and development topics
- Provided technical customer support and project management
- Prepared technical documentation and evaluated customer inquiries (drawings, CAD, standards, specifications)
- Organized meetings and workshops with customers, suppliers, and internal departments
- Developed casting concepts and conducted feasibility studies
- Coordinated modifications of molds and trimming tools with suppliers
- Reengineered and optimized 3D data for molds and die-cast parts
- Created raw part and tool drawings
- Managed data and drawings, including IT ticket system and customer interface
- Conducted CT scans, evaluations, and defect analyses of series and prototype parts
- Extensive experience with products including valve and slider housings, oil distribution plates (8F-DCT), upper and lower housings (DL382), battery trays, and shock tower
Junior Simulation Specialist at Martinrea Honsel GmbH (2012-02 – 2013-03)
- Performed design tasks
- Created, conducted, and evaluated mold-filling and solidification simulations
- Assessed results and prepared detailed presentations
