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The HPDC Die Repair Technician is responsible for the repair, maintenance, troubleshooting, and improvement of high-pressure die casting dies, trim dies, and related tooling. This position ensures tooling is maintained to production and quality standards while minimizing downtime and maximizing die life. The technician works closely with production, engineering, tool room personnel, and maintenance teams to support safe, efficient, and cost-effective manufacturing operations.
Key Responsibilities
· Perform preventive maintenance, repairs, and rebuilds on HPDC dies, trim dies, and associated tooling.
· Disassemble, inspect, troubleshoot, and reassemble die cast tooling components.
· Diagnose tooling failures and determine corrective actions to restore production readiness.
· Repair worn, damaged, or cracked die components using welding, machining, polishing, grinding, and fitting techniques.
· Perform bench work including spotting, fitting, lapping, and polishing of die surfaces.
· Maintain cooling lines, vent systems, ejector systems, and moving die components.
· Interpret engineering drawings, die designs, blueprints, and tooling specifications.
· Conduct dimensional inspections using precision measuring instruments.
· Assist in die tryouts and production startups following repairs or modifications.
· Document maintenance activities, repair history, and tooling performance data.
· Recommend tooling improvements to enhance die life, casting quality, and productivity.
· Work with engineering teams on die modifications and continuous improvement initiatives.
· Ensure compliance with all safety, environmental, and quality requirements.
· Support emergency tooling repairs to minimize production downtime
Required Qualifications
· High school diploma or GED required.
· Technical training, apprenticeship, or certification in Tool & Die, Machining, or a related field preferred.
· Experience repairing and maintaining HPDC dies and tooling.
· Proficiency with hand tools, precision measuring instruments, and tool room equipment.
· Ability to read and interpret mechanical drawings, blueprints, and CAD-generated prints.
· Knowledge of die casting processes, die construction, and tooling materials.
· Strong mechanical troubleshooting and problem-solving skills.
· Ability to work independently and as part of a team.
Preferred Qualifications
· 3+ years of experience in high-pressure die casting tooling repair.
· Experience with aluminum die casting operations.
· TIG welding, laser welding, or tool steel repair experience.
· Knowledge of CNC machining, EDM, surface grinding, and milling operations.
· Familiarity with lean manufacturing and continuous improvement principles.
· Experience using maintenance management systems (Work Instructions or visual aids)
Technical Skills
· Die disassembly and assembly
· Tool steel repair techniques
· Die spotting and fitting
· Welding and polishing
· Precision measurement tools
· Blueprint reading
· Hydraulic and mechanical systems
· Root cause analysis
· Preventive maintenance practices
· Problem-solving and troubleshooting
Physical Requirements
· Manufacturing and tool room environment.
· Exposure to heat, noise, oils, lubricants, and metalworking equipment.
· Required use of personal protective equipment (PPE) including safety glasses, hearing protection, gloves, and steel-toed footwear.
Performance Metrics (Support cross functional team)
· Tooling downtime reduction
· Die repair turnaround time
· Die life improvement
· First-pass casting quality
· Preventive maintenance completion rate
· Scrap reduction related to tooling issues
· Safety and quality compliance
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