Sr. Manufacturing Controls Dev Engineer, Simulations, Castings

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

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