Senior Engine Design Engineer in Auburn Hills, Michigan at FEV North America Inc

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

• 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

Equal opportunity employer as to all protected groups, including protected veterans and individuals with disabilities