Product Design Engineer – ADAS Radar Mounting Solutions

Ford • Dearborn, MI

14d

About The Position

Lead Product Design: Own the end-to-end design of radar brackets or other mounting interface using CATIA V6/V5, moving from initial concept through to SOP (Start of Production). Material Selection: Determine the best material applications (e.g., glass-filled polymers, stamped steel) based on weight, cost, durability and performance over the life of the product. Structural Analysis: perform FEA (Finite Element Analysis) to predict modal frequencies and vibration targets to ensure the bracket doesn't resonate with engine or road frequencies and withstand long-Term "Creep" and Heavy-Duty Life Cycles. Advanced GD&T: Apply advanced Geometric Dimensioning and Tolerancing to ensure sensor alignment remains within the required degrees from vehicle centerline. Statistical Knowledge: Utilize Design for Six Sigma (DFSS) principals to conduct complex 3D tolerance stack-ups. This includes managing Critical-to-Quality (CTQ) dimensional capability metrics (e.g., SPC and PIST) and defining gauge expectations to ensure high-volume production parts meet strict tolerances. Cross-Functional Collaboration: Partner with radar supplier and ADAS core teams to apply performance/functional requirements to the bracket design considerations Tooling & DFM: Lead Tooling Design Reviews (TDR) with injection molding suppliers. Drive optimization of gate locations, parting lines, and draft angles to minimize warpage—critical for maintaining radar boresight accuracy. Supplier Technical Management (Build-to-Print): Act as the primary technical lead for manufacturing partners. You will manage the hand-off of engineering CAD data and drawings to suppliers and ensure they execute the design to exact specifications. Manufacturing Readiness & PPAP: Facilitate and oversee the Production Part Approval Process (PPAP). Review supplier submissions, including Dimensional Results, Control Plans, and PFMEAs, to ensure the manufacturing process is capable of producing parts that meet design intent. Radar Performance Integrity: Ensure the bracket maintains precise boresight alignment and limits "sensor jitter" to within specified tolerances (e.g., of deflection). Interface & Packaging Management: Collaborate with Studio (Styling) and Body Engineering to package sensors behind fascias or grilles. Ensure "keep-out" zones and Field of View (FOV) requirements are met. Account for harness routing, connector "click-space," and strain relief to support long-term mounting durability. Validation Oversight: Define and lead DV/PV (Design Verification/Production Verification) testing with buy-in from radar core stakeholders. Ensure parts pass all environmental, thermal, and mechanical shock tests required for the segment.

Requirements

• Bachelor's Degree in Mechanical Engineering or related field of study
• 5+ years of experience in automotive mechanical design, specifically with structural injection-molded plastics and steel components.
• Strong understanding of injection molding and sheet metal stamping processes
• Experience with the APQP/PPAP process and working with Tier 1/Tier 2 suppliers in a build-to-print environment.
• Strong understanding of GD&T (ASME Y14.5)
• Proven track record of managing tooling timelines and resolving manufacturing non-conformances.
• Knowledge of and experience performance FEA (Finite Element Analysis)

Nice To Haves

• Master's Degree in Mechanical Engineering or related field of study
• 10+ years of experience in automotive mechanical design, specifically with structural injection-molded plastics and steel components.
• Expert level CAD experience in Catia V5/V6 modeling software
• Experience in understanding high-vibration environments (such as Super Duty or Heavy Truck segment)
• Application of GD&T and component design principles in controlling sensor alignment
• Familiarity with radar sensor theory (e.g. how material properties, interface thicknesses and bracket tilt affect wave propagation).
• Experience with Teamcenter PLM for releasing engineering drawings and managing BOMs.

Responsibilities

• Own the end-to-end design of radar brackets or other mounting interface using CATIA V6/V5, moving from initial concept through to SOP (Start of Production).
• Determine the best material applications (e.g., glass-filled polymers, stamped steel) based on weight, cost, durability and performance over the life of the product.
• Perform FEA (Finite Element Analysis) to predict modal frequencies and vibration targets to ensure the bracket doesn't resonate with engine or road frequencies and withstand long-Term "Creep" and Heavy-Duty Life Cycles.
• Apply advanced Geometric Dimensioning and Tolerancing to ensure sensor alignment remains within the required degrees from vehicle centerline.
• Utilize Design for Six Sigma (DFSS) principals to conduct complex 3D tolerance stack-ups. This includes managing Critical-to-Quality (CTQ) dimensional capability metrics (e.g., SPC and PIST) and defining gauge expectations to ensure high-volume production parts meet strict tolerances.
• Partner with radar supplier and ADAS core teams to apply performance/functional requirements to the bracket design considerations
• Lead Tooling Design Reviews (TDR) with injection molding suppliers. Drive optimization of gate locations, parting lines, and draft angles to minimize warpage—critical for maintaining radar boresight accuracy.
• Act as the primary technical lead for manufacturing partners. You will manage the hand-off of engineering CAD data and drawings to suppliers and ensure they execute the design to exact specifications.
• Facilitate and oversee the Production Part Approval Process (PPAP). Review supplier submissions, including Dimensional Results, Control Plans, and PFMEAs, to ensure the manufacturing process is capable of producing parts that meet design intent.
• Ensure the bracket maintains precise boresight alignment and limits "sensor jitter" to within specified tolerances (e.g., of deflection).
• Collaborate with Studio (Styling) and Body Engineering to package sensors behind fascias or grilles. Ensure "keep-out" zones and Field of View (FOV) requirements are met. Account for harness routing, connector "click-space," and strain relief to support long-term mounting durability.
• Define and lead DV/PV (Design Verification/Production Verification) testing with buy-in from radar core stakeholders. Ensure parts pass all environmental, thermal, and mechanical shock tests required for the segment.

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: Mid Level