Design Integration Engineer – Cast Body Structures

Job Title

In this role, you will be responsible for leading product development and integration activities for large, high pressure die casting-based Body Structures. This includes applying engineering tools and processes and knowledge of casting and vehicle manufacturing to successfully develop components and systems, while achieving program imperatives. Your technical leadership will be required to coach designers and engineers to complete the advanced stages of product design, emphasizing maximum manufacturing efficiency.

This role requires a wide range of creativity and latitude to solve complex problems with originality, creativity, and a wide application of principles, theories, and concepts. The role also involves endorsing alternative approaches to improve quality of product design, as well as recommending strategy and policy procedures for long term success.

What You'll Do

Demonstrate a deep understanding, and the ability to lead a team, to incorporate lightweighting concepts into aluminum body structures to minimize overall vehicle mass while maintaining structural integrity

Expertise in the manufacturing and application of high pressure die castings (HPDC) in aluminum body structures with the ability to ensure optimal trade-offs between mass reduction, manufacturability, and mechanical performance

Expertise in the familiarity and understanding of aluminum cast material properties (Strength, Alloys, Elongation) in designing for appropriate U/B applications

Expertise in the design of cast aluminum cross-sections & rib pattern configurations to maximize structural STRENGTH and STIFFNESS while maintaining castability

Expertise in aluminum cast bonding and joining, with knowledge of surface adhesive preparation and industry standard fastening methods to augment adhesive joining

Expertise in integrating features into aluminum castings for connections to adjacent subsystems, with a focus on minimizing secondary processing operations

Launch integrated aluminum cast, stamped, and extruded underbody components into mass production, with clear contributions from vehicle concept to production

Apply overall strong technical knowledge of under body structures – components, systems, subsystems, requirements, validation, load paths, best practices & interfacing systems

Work with System Architects to apply sound DFM concepts, particularly as they relate to die castings to design robustly manufacturable, defect-free products that meet structural requirements

Promote Engineering with Simplicity efforts to reduce part count and simplify manufacturing processes. Maximize integration opportunities created with cast components

Ensure that GD&T strategy matches dimensional capability and assembly strategy for all components

Your Skills & Abilities (Required Qualifications)

Bachelor of Science – Engineering

10+ years of experience in casting body structures

Detailed knowledge of manufacturing processes including casting, stamping, vehicle assembly process (BOP) & dimensional strategies

Ability to understand and interpret CAE and act on Validation results

Guide on engineering operations, processes, and best practices

Extensive understanding of Specification and Release terms and systems

Experience at all phases of a vehicle program

Show leadership skills and ability to motivate and mentor others

Ability to think strategically and look across all programs variants for an architecture for efficient and consistent solutions

Extensive level of analytical ability where problems are complex, difficult.

Demonstrated ability of 'dealing with ambiguity' to enable timely decision making.

What Will Give You a Competitive Edge (Preferred Qualifications)

Master of Science

DFSS Certification (Black Belt)