Design Release Engineer - Engine Structures

Stellantis•Auburn Hills, MI

About The Position

The Design Release Engineer for Engine Structural Components is responsible for the design, development, and technical leadership in the creation, validation, and release of internal combustion structural components for Stellantis’ vehicles. This includes Cylinder Blocks, Cylinder heads, Bed Plates, Cam Carriers, and other critical structural components that ensure the performance and integrity of the engine. The role involves driving the design through all phases of the product lifecycle, including design concept, engineering validation, and production release through PPAP (Production Part Approval Process).

Requirements

Bachelor's degree in Mechanical Engineering or related degree field.
A minimum of 5 years of relevant experience working with design and manufacturing of structural components, specifically metal casting
Understanding of structural components are related manufacturing processes, i.e. aluminum casting, machining, etc.
Understanding of product development documentation such as, DFMEA and DVP&R.
Understanding of Mechanics of Materials, Sealing systems, CAE Analysis, and GD&T.
Experience in selecting materials and manufacturing methods for mechanical components.
Ability to author system/component level requirements.
Strong interpersonal communication, team/leadership skills/experience.
Strong oral and written communication skills.
Strong project management skills/experience.
Demonstrated understanding of structural analysis and failure modes of complex mechanical systems.

Nice To Haves

Advanced degree in Mechanical Engineering with emphasis manufacturing of casted/stamped components of aluminum and steel.
Working experience in creation and execution of validation plans.
Critical character traits to ensure success: Action Oriented, Dealing with Ambiguity, Customer Focus, Problem Solving.
Working experience with 3D cad programs, preferably Siemens NX
8+ years of relevant experience working with design and manufacturing of structural components, including metal stamping and casting.

Responsibilities

Lead the design of engine structural components, ensuring alignment with vehicle and engine requirements.
Develop and refine concepts for Cylinder Blocks, Cylinder heads, Bed Plates, Cam Carriers based on functional, safety, and performance requirements.
Support CAD modeling, FEA (Finite Element Analysis), and other design validation methods to ensure structural integrity and compliance with standards.
Collaborate with other engineering teams (materials, electrical, thermal, packaging, validation) to integrate structural components into the overall engine architecture.
Manage design release activities from early concept through production, including the timely completion of B-Sample, C-Sample, X0, X1, X2, and X3 milestones.
Own the Bill of Materials (BOM) and Engineering Change Notices (ECNs) for structural components.
Ensure all parts meet quality, cost, and timing requirements.
Drive the Production Part Approval Process (PPAP) for engine structural components, ensuring compliance with all regulatory and customer specifications.
Coordinate with cross-functional teams, including manufacturing, suppliers, and quality, to ensure the successful release and implementation of designs.
Provide technical leadership and support during the development and production stages to resolve design issues, material selection challenges, and process-related problems.
Lead DFMEA (Design Failure Mode and Effects Analysis) and other risk assessment activities to ensure design robustness and mitigate potential issues.
Participate in the development of testing strategies for structural components, including dyno/vehicle durability, material, component, and thermal testing.
Work closely with suppliers to ensure design feasibility, cost competitiveness, and manufacturability of structural components.
Collaborate with validation teams to define and implement validation testing, ensuring structural components meet functional and performance metrics.
Partner with vehicle integration teams to ensure proper fitment, safety, and integration of engine structural components into the overall vehicle platform.
Develop and maintain engineering documentation, including design specifications, drawings, test plans, and validation reports.
Ensure that all technical documentation is up-to-date and aligns with program timelines and PPAP requirements.
Report on project status, timelines, and risk assessments to senior management and stakeholders.