Mechanical Design Engineer - Thermal Systems

Job Overview

We are looking for a proficient Mechanical Design Engineer to join our Thermal Systems Team. This role demands hands-on expertise in automotive product design, particularly focusing on thermal systems and associated parts like HVAC modules, ducts, hoses, heat exchangers, and cooling components.

Key Responsibilities

• Design and develop thermal system components such as HVAC modules, air ducts, hoses, heat exchangers, cooling modules, and other thermal management parts.
• Lead the end-to-end product design and development process from conception to release.
• Create injection molded plastic and metal component designs, considering material selection, design for manufacturing (DFM), design for assembly (DFA), and tooling feasibility.
• Conduct thermal performance assessments and assist with thermal simulations across various operating conditions.
• Analyze and act upon CAE reports, working closely with CAE teams to enhance designs.
• Develop and manage 3D CAD models, 2D drawings, bills of materials (BOMs), and engineering release documents.
• Support prototype assembly, testing, validation, and resolving issues.
• Investigate and address thermal performance challenges during product development and manufacturing phases.
• Collaborate with suppliers to evaluate designs, tooling, manufacturability, and validate requirements.
• Engage in design for failure mode and effects analysis (DFMEA), design verification plans and reports (DVP&R), design reviews, and manage engineering changes.
• Ensure compliance with automotive standards, quality expectations, and engineering best practices.
• Oversee the release of designed components as part of the product development cycle.

Required Qualifications

• Bachelor's degree in Mechanical Engineering or a closely related field.
• At least three years of experience designing automotive thermal systems.
• Demonstrated background with HVAC modules, air duct systems, hoses, heat exchangers, and automotive cooling components.
• Solid understanding of heat transfer, fluid dynamics, and thermal management systems.
• Experience in designing injection molded plastic and metal components, including material selection and DFM/DFA considerations, as well as tooling.
• Proficient knowledge of GD&T, tolerance stack-up analysis, and product development processes.
• Hands-on experience supporting prototype builds and validation tasks.

Essential Technical Skills

• Expertise in CATIA V6 software.
• Proven track record in automotive product design and development.
• Specialized skills in HVAC and thermal systems engineering.
• Design capabilities for injection molded plastic parts and metal components.
• Strong foundation in design for manufacturing and assembly principles.
• Ability to interpret and utilize CAE reports effectively.
• Experience working effectively with cross-functional engineering teams.

Preferred Qualifications

• Knowledge of automotive development processes and product release workflows.
• Familiarity with DFMEA, DVP&R, advanced product quality planning (APQP), validation, and testing methods.
• Experience collaborating with suppliers and global teams.
• Ability to diagnose and resolve thermal system and cooling performance issues.
• Excellent verbal and written communication skills.