Prototyping Engineer - Casting and Molding

📍 Job Overview

Job Title: Prototyping Engineer - Casting and Molding Company: Meta Location: Sunnyvale, CA Job Type: Full-time Category: Engineering / Manufacturing Operations Date Posted: 2025-10-03 Experience Level: 5-10 Years Remote Status: On-site

🚀 Role Summary

• This role is pivotal in Meta Reality Labs' mission to connect the world through advanced hardware development, focusing on the design and production of physical prototypes.
• The Prototyping Engineer will leverage expertise in casting and molding processes, including 3D printing and CNC machining, to rapidly iterate on complex electro-mechanical designs.
• This position requires a blend of hands-on manufacturing, CAD design, and automation skills to optimize internal processes and accelerate the transition from concept to functional prototype.
• The engineer will collaborate extensively with mechanical engineering teams, providing critical feedback on part manufacturability and ensuring high-quality output from a state-of-the-art prototyping facility.

📝 Enhancement Note: This role is positioned within the highly dynamic and fast-paced environment of Meta Reality Labs, implying a strong emphasis on innovation, rapid iteration, and the successful delivery of cutting-edge hardware prototypes. The focus is less on traditional GTM operations and more on the foundational engineering and manufacturing operations that enable product development.

📈 Primary Responsibilities

• Design and produce molds for various materials (plastics, hard metals, silicones) using 3D printed and machined tools.
• Implement Design for Additive Manufacturing (DFAM) principles to optimize designs for 3D printing and other rapid prototyping processes.
• Develop and automate internal niche processes within the prototyping facility to enhance efficiency and reduce lead times.
• Perform safe setup, operation, and maintenance of advanced fabrication equipment, including industrial 3D printers, 5-axis and 3-axis CNC machines, laser cutters, waterjet cutters, and injection molding machines.
• Collaborate closely with mechanical and design engineers to debug designs, provide feedback on part functionality, and advise on suitability for production.
• Manage the specification and procurement of tooling and fixtures required for prototyping and low-volume production.
• Ensure the safe operation of the prototyping shop, maintaining adequate material supplies and adhering to all safety protocols.
• Conduct part quality inspections and ensure that manufactured components meet stringent design specifications.
• Communicate project timelines, expectations, and potential manufacturing challenges clearly to cross-functional teams and stakeholders.
• Drive continuous improvement initiatives within the prototyping facility to enhance systems, tools, and overall operational efficiency.

📝 Enhancement Note: The responsibilities highlight a strong hands-on and problem-solving orientation, characteristic of advanced R&D prototyping roles. The inclusion of automation and continuous improvement suggests a forward-thinking approach to manufacturing operations within Meta's product development lifecycle.

🎓 Skills & Qualifications

Education:

• Bachelor's degree in a relevant design or engineering field (e.g., Mechanical Engineering, Manufacturing Engineering, Industrial Design).

Experience:

• 5+ years of direct experience in a rapid prototyping environment, with a focus on casting and molding processes.
• Proven experience in designing, fabricating, and troubleshooting molds for various materials.
• Demonstrated experience taking products from concept through to functional prototype or early production stages.

Required Skills:

• Hands-on experience operating and maintaining industrial 3D printers and CNC machine tools.
• Proficiency in Computer-Aided Design (CAD) software such as Autodesk Fusion, Siemens NX, Solidworks, Rhino, Cimatron, or similar.
• Experience with scripting or programming languages (e.g., Python, Grasshopper) for design automation and workflow enhancement.
• Strong understanding of various prototyping technologies including CNC machining, laser cutting, waterjet cutting, and injection molding.
• Familiarity with prototyping complex electro-mechanical assemblies and associated shop tools.
• Excellent problem-solving skills with a proactive approach to identifying and implementing novel solutions in rapid prototyping.
• Ability to quickly learn and efficiently utilize new software and technologies.
• Strong communication skills, with the ability to clearly articulate technical concepts and project timelines to diverse teams.

Preferred Skills:

• Experience with software like Magics for 3D printing preparation and optimization.
• Basic software engineering skills and coding fundamentals with a focus on manufacturing and automation.
• Exposure to code management practices (e.g., Git).
• Experience using 3D printing and advanced manufacturing techniques in regulated industries (consumer products, automotive, aerospace, medical).
• Broad experience in diverse 3D printing technologies and their specific applications.
• Experience managing or mentoring technicians on daily responsibilities.

📝 Enhancement Note: The emphasis on both CAD design and software/coding skills indicates a role that bridges traditional engineering with modern automation and digital manufacturing techniques, aligning with Meta's tech-forward ethos. The preference for experience in regulated industries suggests a commitment to quality and reliability in prototype development.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Showcase a minimum of 3-5 distinct projects demonstrating expertise in mold design and fabrication for various materials and applications.
• Include detailed case studies of successful prototype development cycles, highlighting challenges overcome and innovative solutions implemented.
• Provide examples of process optimization or automation projects undertaken within a prototyping or manufacturing setting, with measurable efficiency gains.
• Demonstrate proficiency with CAD software through complex design examples, including mold flow analysis or simulation outputs where applicable.
• Evidence of experience with a range of prototyping technologies (3D printing, CNC, injection molding) and their integration into a cohesive workflow.

Process Documentation:

• Documented examples of workflow design and optimization for rapid prototyping processes, including turnaround time improvements.
• Case studies detailing the implementation of automation solutions for mold making or part finishing.
• Analysis of performance metrics related to prototype quality, yield, and production efficiency from past projects.
• Examples of how feedback loops with design engineering were established and utilized for iterative design improvements.

📝 Enhancement Note: A strong portfolio is crucial for this role, as it serves as tangible proof of the candidate's hands-on skills and problem-solving capabilities in a highly practical engineering discipline. The focus is on demonstrating a systematic approach to prototyping challenges and a commitment to continuous process improvement.

💵 Compensation & Benefits

Salary Range:

• Estimated Range: $120,000 - $180,000 annually, based on experience level, specific skill set, and Meta's compensation philosophy for engineering roles in Sunnyvale, CA.
• Methodology: This estimate is derived from industry benchmarks for Prototyping Engineers and advanced manufacturing roles in the highly competitive Silicon Valley tech market, considering Meta's typical compensation bands for similar positions. Factors such as years of experience, specific technical proficiencies (e.g., advanced automation, niche CAD software), and educational background are considered.

Benefits:

• Comprehensive health, dental, and vision insurance plans.
• Generous paid time off (PTO) and holiday schedule.
• 401(k) retirement savings plan with company match.
• Stock options and potential for performance-based bonuses.
• Access to extensive learning and development resources, including internal training and external certifications.
• On-site amenities and employee wellness programs.
• Relocation assistance may be available for qualified candidates.
• Opportunities to work with cutting-edge technology and contribute to groundbreaking products.

Working Hours:

• Standard 40-hour work week, with flexibility expected to meet project deadlines and operational needs.
• Occasional overtime may be required to support critical prototype builds or resolve urgent manufacturing issues.

📝 Enhancement Note: The salary range is an estimate for the Sunnyvale, CA location and the specified experience level, reflecting Meta's competitive compensation strategy for technical talent in the Bay Area. Benefits are typical for large tech organizations and are designed to attract and retain top engineering talent.

🎯 Team & Company Context

🏢 Company Culture

Industry: Technology / Social Media / Virtual & Augmented Reality Company Size: Large Enterprise (10,000+ employees) Founded: 2004 Company Description: Meta's mission is to give people the power to build community and bring the world closer together. Reality Labs is at the forefront of this mission, developing the hardware and software that will define the next era of social connection and immersive experiences. The company fosters a culture of rapid innovation, data-driven decision-making, and a strong emphasis on engineering excellence.

Team Structure:

• The Prototyping Engineer will be part of the Meta Reality Labs division, likely within a dedicated Mechanical Prototyping Facility or a broader hardware engineering team.
• The team comprises skilled engineers, technicians, and designers focused on bringing new hardware concepts from ideation to tangible prototypes.
• Reporting structure likely involves a Senior Engineering Manager or Director overseeing the prototyping operations and hardware development roadmap.
• Close collaboration is expected with mechanical design engineers, electrical engineers, product managers, and potentially software engineers working on embedded systems.

Methodology:

• Data-Driven Iteration: Decisions regarding design and process improvements are informed by rigorous testing, simulation, and performance data.
• Agile Development: The team operates with a sense of urgency, employing agile methodologies to accelerate development cycles and respond quickly to design feedback.
• Continuous Improvement: A strong emphasis is placed on identifying inefficiencies and implementing solutions to enhance processes, tools, and overall output quality.
• Cross-Functional Collaboration: Open communication and collaboration across different engineering disciplines are essential for successful product development.

Company Website: https://www.meta.com/

📝 Enhancement Note: Meta's culture is characterized by its scale, speed, and ambition. For an operations-focused role like this, it means operating within a highly structured yet fast-paced environment where individual contributions significantly impact product timelines and innovation.

📈 Career & Growth Analysis

Operations Career Level: This role is positioned as an experienced individual contributor within the engineering and operations domain of hardware development. It sits beyond entry-level and junior roles, requiring significant technical depth and practical experience.

Reporting Structure: The Prototyping Engineer will report to a management layer within the Reality Labs hardware engineering or prototyping operations group. This manager will oversee project assignments, performance reviews, and career development guidance. The role also entails significant collaboration with peer engineers and potential mentorship of junior technicians.

Operations Impact: The Prototyping Engineer's work directly impacts Meta's ability to rapidly innovate and develop next-generation hardware for Reality Labs. By efficiently producing high-fidelity prototypes, this role accelerates the product development lifecycle, enabling faster testing, validation, and iteration, which is critical for Meta's ambitious product roadmap in the metaverse.

Growth Opportunities:

• Technical Specialization: Deepen expertise in advanced manufacturing techniques, specific materials, or emerging prototyping technologies (e.g., novel 3D printing processes, advanced robotics in manufacturing).
• Process Engineering Leadership: Transition into roles focused on defining and scaling manufacturing processes, automation strategies, or quality control systems for larger-scale production.
• Cross-Functional Mobility: Move into roles within mechanical engineering, product development, or even operations management within other divisions of Meta.
• Project Management: Develop skills in managing complex prototyping projects, coordinating resources, and ensuring timely delivery.
• Mentorship & Team Leadership: Take on responsibilities for guiding junior engineers and technicians, potentially leading small project teams.

📝 Enhancement Note: Meta offers extensive internal growth paths. For a Prototyping Engineer, career progression can lead to deeper technical mastery, broader operational responsibilities, or movement into product development leadership, aligning with Meta's commitment to employee development and internal talent mobility.

🌐 Work Environment

Office Type: This role is based in a state-of-the-art mechanical prototyping facility within Meta's Sunnyvale campus. It's a hands-on environment that combines advanced machinery with collaborative workspace areas.

Office Location(s): Sunnyvale, California, USA. This location is part of Meta's significant presence in Silicon Valley, offering access to a vibrant tech ecosystem.

Workspace Context:

• Hands-On Manufacturing: Significant time will be spent on the shop floor operating and maintaining advanced machinery. This requires comfort with a dynamic and potentially noisy environment.
• Collaborative Design Spaces: Adjacent areas will be available for CAD work, design reviews, and collaboration with engineering teams, equipped with necessary computer hardware and software.
• Access to Tools & Technology: The facility is equipped with a comprehensive suite of advanced prototyping tools, including cutting-edge 3D printers, CNC machines, and metrology equipment.
• Team Interaction: Frequent interaction with a dedicated team of engineers and technicians, fostering a collaborative and knowledge-sharing atmosphere.

Work Schedule: The standard work schedule is 40 hours per week. However, given the nature of rapid prototyping and product development, there may be periods requiring flexible hours or occasional overtime to meet critical project deadlines. The emphasis is on delivering results and meeting aggressive timelines.

📝 Enhancement Note: The work environment is a blend of a high-tech manufacturing floor and a collaborative engineering office. Candidates should be comfortable with both aspects, understanding that production demands can influence the work schedule.

📄 Application & Portfolio Review Process

Interview Process:

• Initial Screening: A recruiter will review applications and conduct an initial screening call to assess basic qualifications, interest, and cultural fit.
• Technical Phone/Video Interview: Expect a technical discussion with an engineering manager or senior team member. This will likely cover your experience with CAD, prototyping processes, specific machinery (3D printers, CNC), and problem-solving approaches.
• On-Site/Virtual On-Site Interviews: This stage typically involves multiple back-to-back interviews with different team members, including:
  • Technical Deep Dive: In-depth questions about your experience with mold design, materials, automation, and manufacturing challenges.
  • Portfolio Presentation: A dedicated session to present your portfolio, discussing specific projects, your role, the impact, and the processes used. Be prepared to walk through CAD models or design files.
  • Behavioral & Situational Questions: Assessing your teamwork, communication, problem-solving under pressure, and adaptability. Questions might include how you've handled design failures or tight deadlines.
  • Case Study/Problem-Solving Exercise: You might be given a hypothetical design or manufacturing problem to solve, demonstrating your analytical and creative thinking.
• Hiring Manager Interview: A final conversation with the hiring manager to discuss overall fit, career aspirations, and the specific team dynamics.

Portfolio Review Tips:

• Curate Selectively: Showcase 3-5 of your strongest, most relevant projects that highlight mold design, advanced manufacturing, automation, and problem-solving.
• Quantify Impact: For each project, clearly articulate the problem, your solution, the technologies used, and the measurable outcomes (e.g., reduced lead time by X%, improved part quality by Y%, enabled a critical design iteration).
• Detail Your Role: Be specific about your individual contributions, especially if it was a team project.
• Showcase Process: Explain your workflow, design considerations, material selection rationale, and any automation or optimization steps you implemented.
• Visual Aids: Use high-quality images, CAD renderings, videos of the machinery in action, or even physical prototypes if feasible for on-site interviews. For virtual interviews, ensure screen sharing is seamless.
• Be Ready for Deep Dives: Anticipate detailed questions about your design choices, challenges encountered, and how you overcame them.

Challenge Preparation:

• Understand the Tools: Refresh your knowledge of common CAD software (Fusion 360, NX, Solidworks), CAM principles, and the operational nuances of industrial 3D printers and CNC machines.
• Problem-Solving Framework: Practice breaking down complex problems into smaller, manageable parts. Think about constraints, available resources, and potential solutions.
• Communication is Key: Prepare to clearly articulate your thought process, assumptions, and proposed solutions, even if you don't reach a perfect answer.
• Focus on Efficiency: Given Meta's culture, be ready to discuss how you would approach a problem with speed and efficiency in mind, balancing quality with turnaround time.

📝 Enhancement Note: The interview process at Meta is rigorous and designed to assess a candidate's technical depth, problem-solving skills, and cultural alignment. A well-prepared portfolio and clear communication of technical concepts are paramount for success in this engineering role.

🛠 Tools & Technology Stack

Primary Tools:

• CAD Software: Autodesk Fusion 360, Siemens NX, Solidworks, Rhino (proficiency in at least one is critical; experience with multiple is a plus).
• CAM Software: Integrated within CAD packages or standalone for CNC programming.
• 3D Printing: Industrial-grade 3D printers (e.g., FDM, SLA, SLS technologies). Candidates should be familiar with machine setup, operation, and maintenance.
• CNC Machining: 3-axis and 5-axis CNC machines for milling and turning. Experience with machine setup, tool selection, and basic G-code understanding is beneficial.
• Injection Molding: Experience with setting up and operating injection molding machines for prototype parts.
• Scripting/Automation: Python, Grasshopper, or similar for parametric design and process automation.

Analytics & Reporting:

• Metrology Tools: Calipers, micrometers, CMM (Coordinate Measuring Machine) for part inspection and quality control.
• Data Analysis Software: Basic proficiency in spreadsheet software (e.g., Excel, Google Sheets) for tracking part quality, material usage, and machine uptime.

CRM & Automation:

• Project Management Software: Familiarity with tools like Jira, Asana, or internal Meta equivalents for task tracking and collaboration.
• Digital Asset Management (DAM) Systems: Potentially used for managing CAD files and project documentation.
• Version Control Systems: Exposure to Git or similar for managing design iterations and code (if applicable to automation scripts).

📝 Enhancement Note: Proficiency in a range of CAD/CAM software and hands-on experience with industrial 3D printers and CNC machines are non-negotiable. The inclusion of scripting and automation tools points towards a role that values efficiency and modern manufacturing practices.

👥 Team Culture & Values

Operations Values:

• Innovation: A drive to explore new materials, processes, and technologies to push the boundaries of what's possible in prototyping.
• Speed & Agility: Commitment to rapid iteration and quick turnaround times, essential for fast-paced product development.
• Quality & Precision: A meticulous approach to design, fabrication, and inspection to ensure prototypes accurately represent intended functionality and form.
• Collaboration: Valuing open communication, knowledge sharing, and mutual support across engineering disciplines and teams.
• Problem-Solving: A proactive and persistent attitude towards identifying and resolving complex manufacturing and design challenges.
• Continuous Improvement: A mindset focused on constantly seeking ways to optimize processes, tools, and workflows for greater efficiency and effectiveness.

Collaboration Style:

• Cross-Functional Integration: Seamless collaboration with mechanical engineers, designers, and potentially electrical and software engineers to ensure prototypes meet all project requirements.
• Feedback Loops: Active participation in design review meetings, providing constructive feedback on manufacturability and offering alternative solutions.
• Knowledge Sharing: Willingness to share expertise on manufacturing processes, material properties, and tooling with team members and stakeholders.
• Results-Oriented: A shared focus on achieving project milestones and delivering functional prototypes that enable critical product decisions.

📝 Enhancement Note: Meta fosters a culture that values both individual technical prowess and collaborative problem-solving. The emphasis on speed, innovation, and quality is paramount, reflecting the demanding nature of hardware development in the VR/AR space.

⚡ Challenges & Growth Opportunities

Challenges:

• Rapid Iteration Demands: Balancing the need for speed with the complexity of advanced manufacturing processes to deliver high-quality prototypes on aggressive timelines.
• Material & Process Complexity: Working with a diverse range of materials and manufacturing techniques requires continuous learning and adaptation to unique challenges presented by each.
• Debugging Novel Designs: Troubleshooting issues with novel or complex electro-mechanical assemblies where established solutions may not exist.
• Tooling & Fixture Design: Developing custom tooling and fixtures for unique parts can be time-consuming and requires creative engineering solutions.
• Scaling from Prototype to Production: Bridging the gap between a functional prototype and the considerations for mass production, even if not directly involved in full-scale manufacturing.

Learning & Development Opportunities:

• Advanced Manufacturing Techniques: Access to cutting-edge equipment and training in emerging technologies like new 3D printing methods, advanced CNC programming, or novel casting processes.
• Material Science Exposure: Working with a wide array of polymers, metals, and composites, providing opportunities to deepen understanding of material properties and applications.
• Cross-Disciplinary Learning: Opportunities to learn from mechanical, electrical, and software engineers, broadening understanding of complex product development.
• Process Optimization Training: Access to internal resources and training on Lean Manufacturing, Six Sigma, or other continuous improvement methodologies.
• Industry Conferences & Certifications: Potential for Meta to sponsor attendance at relevant industry events or certifications in specialized manufacturing or design software.

📝 Enhancement Note: This role offers significant opportunities for professional growth by tackling complex engineering challenges and gaining exposure to a wide range of advanced manufacturing technologies and materials, preparing individuals for leadership roles in hardware development and operations.

💡 Interview Preparation

Strategy Questions:

• Process Optimization: "Describe a time you identified an inefficiency in a prototyping process and what steps you took to automate or improve it. What was the impact?" (Focus on quantifiable results, methodology, and problem-solving).
• Design for Manufacturing: "Imagine a complex part design is failing at the injection molding stage. How would you approach diagnosing and resolving this issue, considering both the design and the manufacturing process?" (Demonstrate systematic problem-solving, knowledge of materials, and cross-functional communication).
• Tooling & Fixturing: "Walk me through the process of designing and fabricating a custom fixture for a challenging CNC machining operation." (Highlight planning, CAD skills, material selection, and precision).

Company & Culture Questions:

• Adaptability: "Meta moves incredibly fast. How do you prioritize tasks and manage your time when faced with multiple urgent prototyping requests?" (Showcase organizational skills, ability to triage, and communication under pressure).
• Collaboration: "Describe a situation where you had to collaborate closely with a design engineer who had a vision for a part that seemed difficult to manufacture. How did you work together to find a solution?" (Emphasize communication, empathy, and finding common ground).
• Learning Mindset: "What is a new manufacturing technology or material you've learned about recently, and how might it be applied to Meta's product development?" (Show initiative, curiosity, and forward-thinking).

Portfolio Presentation Strategy:

• The "STAR" Method: For each project, structure your explanation using Situation, Task, Action, and Result. This provides a clear narrative.
• Focus on Impact: Clearly articulate the business or product impact of your work. How did your prototype enable a critical decision, accelerate development, or uncover a key insight?
• Technical Depth: Be prepared to discuss the specific CAD software, machines, materials, and processes you used, along with the technical rationale behind your choices.
• Highlight Problem-Solving: Emphasize any significant challenges you faced and how you creatively overcame them.
• Conciseness: Given the time constraints, be clear, direct, and avoid unnecessary jargon. Practice your presentation to ensure it flows smoothly and stays within the allotted time.

📝 Enhancement Note: Interview preparation should heavily emphasize practical application of skills, problem-solving abilities, and the ability to articulate complex technical concepts clearly. A strong portfolio is your primary tool to demonstrate these capabilities.

📌 Application Steps

To apply for this Prototyping Engineer position:

• Submit your application through the Meta Careers portal.
• Tailor Your Resume: Ensure your resume clearly highlights specific experience with 3D printing, injection molding, CNC machining, CAD design (mentioning specific software), and any automation/scripting experience. Quantify achievements wherever possible (e.g., "Reduced prototype turnaround time by 20%").
• Prepare Your Portfolio: Curate 3-5 of your most impactful projects that showcase your mold design, prototyping, and problem-solving skills. Be ready to present these using the STAR method.
• Research Meta Reality Labs: Understand their current product lines, mission, and recent advancements in VR/AR technology. This will help you tailor your responses and demonstrate genuine interest.
• Practice Technical Explanations: Be ready to verbally walk through complex designs, manufacturing processes, and troubleshooting scenarios. Practice explaining technical details concisely.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and industry-standard assumptions. All details should be verified directly with Meta's hiring team during the application and interview process.