CASTING & WELDING ENGINEER

• Review, audit, and approve 3D CAD models and 2D engineering blueprints (UG/Unigraphics, AutoCAD) for lead-acid battery Cast-On-Strap (COS) molds, water-cooling pathways, and gas venting structures.
• Evaluate thermal expansion and lead-alloy solidification shrinkage mechanics (Pb-Sb / Pb-Ca alloys) to refine mold tolerances and adjust tooling geometry for local Malaysian production lines.
• Plan, track, and oversee mold trial runs (T1/T2/T3) for Cast-On-Strap (COS) molds and terminal welding fixtures, evaluating strap formation quality, lug fusion integrity, and assembly alignment.
• Execute complete physical and dimensional inspections on trial samples, log defect root causes (e.g., mold sticking, cold soldering, pinholes, flash, or strap cracking), and generate formal Mold Acceptance Reports.
• Regulate mold operating temperature windows (495–505°C molten lead pouring range) by conducting water-cooling flow rate tests and optimizing thermal dissipation channels to stabilize cycle times.
• Lead Design Failure Mode and Effects Analysis (DFMEA) and root-cause defect attribution during production spikes, determining failure origins between mold wear, equipment parameters, or lead-alloy impurity variations.
• Formulate technical testing protocols and acceptance thresholds, including weld shear strength, strap pull-out force, electrical discharge stability, and acid corrosion resistance for tropical environments.
• Compile and maintain technical documentation, including product specification sheets, engineering change orders (ECOs), multi-level Bill of Materials (BOMs), explosion diagrams, and bilingual (English/Mandarin) trial histories.
• Collaborate with manufacturing and process engineers to validate design for manufacturability (DFM) and local assembly feasibility, specifically for quick-change tooling, plate lug oxidation controls, and lead ingot purity testing.
• Assess local raw material feasibility, evaluate component standardization across product lines, and account for import tariffs and local supplier machining lead times to optimize unit cost structures.
• Manage spare parts safety stock levels (inserts, ejector pins, cooling nipples) and evaluate local Malaysian toolmaker repair capabilities versus China HQ vendor rework lead times.
• Coordinate technical transfers and maintain alignment between China HQ R&D teams, local Malaysian plant production operations, and external local tooling vendors throughout the product lifecycle.