Emissions Calibration Engineer

Ford Motor • Dearborn, MI

1d • Hybrid

About The Position

The Advanced Emissions Calibration Engineer is responsible for developing and demonstrating system-level capabilities to achieve future emissions targets (SULEV20, SULEV15, and SULEV10) for gasoline-powered Internal Combustion Engines (ICE), Hybrid (HEV), and Plug-in Hybrid (PHEV) applications. This role bridges the gap between virtual simulation and physical validation, leading the development of calibration strategies that balance stringent regulatory compliance with core vehicle attributes like fuel economy and drivability. The ideal candidate combines high-level analytical strategy with a "hands-on" approach to commissioning and debugging complex prototype propulsion systems.

Requirements

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Automotive Engineering, or a related technical field.
• 5+ years of experience in powertrain calibration, with a specific focus on gasoline emissions and/or electrified propulsion systems (HEV/PHEV).
• Proficiency with industry-standard calibration tools (e.g., ATI Vision, ETAS INCA, or Vector CANape) and CAN communication protocols.
• Deep understanding of global emissions regulatory requirements and test procedures, specifically SULEV20, SULEV15, and SULEV10 standards.
• Demonstrated mechanical and electrical (wiring) skills for prototype vehicle/bench setup and hardware-in-the-loop troubleshooting.
• Experience with data acquisition (DAQ) systems and various testing environments, including engine/chassis dynamometers.
• Experience in data engineering and statistical validation, with a proven track record of analyzing large-scale datasets to identify statistically significant trends.

Nice To Haves

• Master’s or PhD in Engineering.
• Expertise design and validation of exhaust aftertreatment.
• In-depth understanding of HEV/PHEV powertrain architectures and their specific impact on emissions (e.g., cold-start management, thermal transients).
• Experience with MATLAB/Simulink and advanced DOE optimization software (e.g., AVL ASCMO, Model-Based Calibration Toolbox).
• Proven ability to lead cross-functional technical reviews and mentor junior calibration engineers.

Responsibilities

• Lead development testing across engine dynamometers, powertrain/hub dynamometers, and physical vehicles.
• Utilize virtual vehicle analytical simulations to front-load calibration development and demonstrate system capability.
• Conduct sensitivity studies to optimize the balance between emissions compliance, fuel economy, performance, and drivability.
• Establish preferred values for control variables using a data-driven approach.
• Synchronize the calibration of various sub-systems—including the engine, aftertreatment (TWC/GPF), transmission, and electric generator/motors—to ensure seamless integration and achievement of emissions targets.
• Utilize Design of Experiments (DOE) methods to efficiently map complex multi-variable calibration spaces and define robust operating strategies.
• Lead the setup and commissioning of prototype systems in both dyno and vehicle environments.
• Perform system-level debugging and troubleshoot complex mechanical, electrical, and software issues.
• Document and present calibration progress, trade-off results, and regulatory compliance status to program leadership and cross-functional teams.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior