The Senior Engine Design Engineer leads the design, development, validation, and production release of internal combustion engine (ICE) and/or hybrid powertrain mechanical components and subsystems. This role is responsible for delivering robust designs that meet performance, durability, packaging, cost, manufacturability, and quality targets. The engineer serves as a technical leader, mentoring others, driving cross-functional execution, and owning complex design problems from concept through production launch.
Product & Component Design Leadership
- Own end-to-end design responsibility for engine hardware (e.g., block, head, valvetrain, crank train, piston/rod, lubrication, cooling, induction/exhaust interfaces, mounting/structures, covers, brackets, accessory drives)
- Manage creation and refinement of 3D CAD models, assemblies, and 2D drawings
- Create and refine GD&T, tolerancing strategy, and fit/function requirements
- Perform concept trade studies and lead design decisions considering performance, cost, risk, packaging, NVH, durability, and serviceability
- Drive design standards and best practices, ensuring compliance with internal standards, industry norms, and safety requirements
Engineering Analysis & Validation
- Develop design solutions guided by FEA/CFD inputs and physical requirements (stress, fatigue, thermal distortion, modal behavior, sealing, wear)
- Define and review test plans (DV/PV, durability, thermal, sealing, corrosion, vibration) and translate test findings into design actions
- Lead root cause investigations for failures (fracture, fatigue, scuffing, oil aeration, overheating, bolt loosening, gasket leaks) using structured methods
- Own component design verification reports and engineering signoffs (design release readiness, deviation approvals, change control justification)
Systems Integration & Cross-Functional Coordination
- Ensure component designs integrate with packaging constraints and system interfaces (mounting, accessory alignment, sealing, routing)
- Support prototype builds, teardowns, plant trials, and field issue triage
Project Execution & Technical Leadership
- Plan and execute work packages: schedule, risk register, technical deliverables, and design reviews
- Lead technical design reviews, manage engineering changes, and ensure clean BOM structure and configuration control
- Mentor junior engineers and designers; review their work for correctness and maturity
- Contribute to strategic technology roadmaps
Requirements
- Must be a US Citizen or Permanent Resident
- Bachelor's degree in Mechanical Engineering or related field (Master's preferred)
- 5+ years of engine or powertrain hardware design experience (or equivalent advanced development experience)
- Strong proficiency with 3D CAD (e.g., CATIA, NX, Creo, SolidWorks) and GD&T
- Demonstrated experience taking designs through prototype - validation - production release
- Solid understanding of materials & manufacturing (cast iron/aluminum, steels, heat treat, surface finishes), mechanical design fundamentals (fatigue, bolted joints, sealing, tribology, thermal expansion), design for quality and reliability (PFMEA, DFMEA, control plans, tolerance stack-up)
- Experience with engineering change management and BOM/configuration control
- Strong knowledge of engine mechanical design principles, CAE methods, and manufacturing processes
- Excellent communication, leadership, and organizational skills
- Ability to participate in defense and export-controlled projects without special licensing
Preferred Qualifications:
- Prior experience working with global OEMs or engineering service providers
- Background in combustion engines for industrial applications (marine, rail, power generation)
- Experience with advanced tools (3D CAD, CAE, 1D simulation, PLM systems)
- Understanding of systems engineering methodologies
- Familiarity with APQP/PPAP, supplier development, and launch support
