Product Development Engineer - Powertrain Cast Structures

Ford • Livonia, MI

5d • $65,100 - $166,200 • Hybrid

About The Position

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!
In this position...
Exciting opportunity to develop the future of Ford Motor Company in the group that designs and releases cast structures components and housings for EV, Hybrid, and ICE Power Units. The automotive industry is quickly working to develop new powertrains to meet evolving customer and market demands, creating an expanding need for new and modified powertrain structures components. Powertrain cast structures components perform many critical functions and are among the most strategic components in a BEV/Hybrid and ICE powertrain. As the engineer for powertrain structures components, you will have the unique opportunity to own all stages of product design, development, and release — from concept to full-scale production — with an emphasis on quality, cost, weight, and functional performance.
The PD Engineer is responsible for managing product release CAD and BOM structures, including assembly positioning and mass attribute analysis. This role also includes facilitating supplier data integration and developing CAD studies to support and drive design improvements.

The PD Engineer is expected to understand and effectively utilize product check-in/check-out processes, version control, data release, and change management within Ford’s PLM ecosystem.

The PD Engineer will perform feasibility analyses using CAD tools, including draft angle analysis, undercut detection, minimum bend radius validation for sheet metal, and clearance checks to support manufacturing and machining requirements.

Requirements

• Bachelor's degree in Engineering, mechanical engineering preferred or similar.
• 2+ years of industry experience with high pressure die cast components and strong knowledge of casting design and best practices.
• 1 year of CAD experience.

Nice To Haves

• Master's degree in Engineering, mechanical engineering preferred or similar.
• Industry experience with aluminum machining, with strong knowledge of machining best practices and GD&T.
• Working knowledge of casting simulation tools (Magma).
• Working knowledge of CAD and CAE (Catia).
• Experience applying 8D, fishbone, and DOE problem-solving methodologies.
• Experience creating Boundary Diagrams, P-Diagrams, and DFMEA.
• Experience reviewing CAE models and CAD drawings.
• Experience maintaining DVP&R and signing off on DV tests.
• Self-starter who can identify improvements and motivate others.
• Strong communication skills with the ability to present information concisely.
• Ability to think like a businessperson while remaining technically astute.
• Ability to manage multiple projects simultaneously.
• Strong leadership, project management, and team-building skills, with a demonstrated ability to work cross-departmentally.
• Strong collaborator, willing to share ideas, documentation, and best practices.
• Excellent oral and written communication skills.
• Proficiency in Microsoft Office (Word, Excel, PowerPoint).

Responsibilities

• Develop cast structures components in conjunction with powertrain systems and internal/external global manufacturing teams.
• Lead component design, validation, and FMA (Failure Mode Analysis).
• Manage prototype and production build delivery and quality.
• Develop structural design to meet powertrain and vehicle attributes including strength, durability, and NVH.
• Lead Purchasing, Finance, and Cost Estimating in supplier selection to achieve program targets
• Interface with engineers of surrounding components and systems (gears, bearings, pumps, mounts, e-motor, etc.).
• Interface with engineers within internal and external manufacturing teams (casting, machining, assembly).
• Release 3-D and 2-D CAD that meets system and component design requirements.
• Support Ford CAE testing of structure design prior to tooling (strength, NVH, casting analysis).
• Support Ford physical testing of structure design.
• Complete FMA and related quality documentation.
• Kick off and track supplier and Ford manufacturing and tooling.
• Lead Ford internal and external supplier CPMT (Component Product Management Team) for assigned components.
• Deliver Final Engineering Sign-off and support production vehicle launch at Ford assembly plants.

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