Product Development Engineer - Heat Exchanger Core Engineer

Ford Motor • Dearborn, MI

8d • Hybrid

About The Position

Ford is seeking a Product Development Engineer to lead heat exchanger components, including condensers, radiators, charge-air coolers, water-cooled condensers, and battery chillers. The role requires expertise in component design, aluminum alloys, brazing and other manufacturing processes, and laboratory analysis. The engineer supports product development across vehicle systems and works with internal teams, laboratories, and suppliers to resolve issues, improve designs, and support global applications.

The position supports the creation and maintenance of core engineering documentation, application-team decisions, component signoffs, validation, manufacturing reviews, and technical problem solving. It also includes managing product release CAD and BOM structures, integrating supplier data, and developing CAD studies for design improvements. The engineer helps optimize refrigerant- and powertrain-related designs for cost, quality, and performance, and supports new technology and supplier development.

This is a hybrid position requiring onsite work four or more days per week. The salary range is $74,300–$166,200, with the final grade and salary based on skills, experience, job scope, responsibility, and market value. Visa sponsorship is not available; candidates must be legally authorized to work in the United States.

Requirements

• Bachelor of Science in Mechanical Engineering, Industrial Engineering, or a related field.
• At least 3 years of experience in heat exchanger designs and development.
• Strong DFMEA knowledge and implementation per AIAG/VDA.
• Laboratory experience in metallurgy related to heat exchangers.
• Knowledge of corrosion laboratory testing and material designs.
• Knowledge of materials and heat exchanger manufacturing processes, including fluxing, brazing, and end-of-line checks.
• Knowledge of investigation tools including SEM, FTIR, surface analysis tools, and TGA.
• Ability to lead and align groups of people who do not directly report to the position.
• Ability to document thermal systems success factors and lessons learned, and teach associated learning sessions.
• Ability to form an opinion, communicate it effectively at all levels, and drive the company in a winning direction.
• Legally authorized to work in the United States; employment eligibility verification is required at hire.

Nice To Haves

• Master of Engineering in electrical engineering, mechanical engineering, physics, systems, or a related area.

Responsibilities

• Support creation and maintenance of Core Engineering Documents, including DFMEA/SCCAF documents, requirements, and test procedures.
• Support application teams with sourcing decisions, validation planning, engineering signoffs, and manufacturing site reviews.
• Sign off on DV/PV/SREA/DPA for heat exchanger components.
• Resolve technical problems related to launches, recalls, quality, and field issues.
• Understand and apply heat exchanger manufacturing processes, including tube and fin forming, stampings, injection molding, brazing, and end-of-line leak checks.
• Understand corrosion methodologies for different heat exchanger types, including rolled tube, extruded tube, and plate stack designs.
• Conduct root cause analysis and work with suppliers on countermeasures and preventative actions.
• Apply knowledge of materials, analysis tools, design, and manufacturing for heat exchanger components.
• Lead technical discussions to deliver optimized refrigerant or powertrain designs for vehicle systems.
• Work with Ford organizations, laboratories, and external suppliers to develop solutions to issues.
• Support global application teams with refrigerant- and coolant-based heat exchanger issues.
• Optimize designs for cost reduction while maintaining quality and performance.
• Interact with Refrigerant, Power Train, NVH, Controls, and CAE teams, and collaborate with internal subsystem Technical Specialists and external suppliers.
• Support new technology and supplier development.
• Support strategy papers such as Modularity and Commodity Business Plan.
• Provide technical support for cost reduction ideas and quality improvements.
• Manage product release CAD and BOM structures, including assembly positioning and mass attribute analysis.
• Facilitate supplier data integration and develop CAD studies to support design improvements.
• Document thermal systems success factors and lessons learned through design rules, requirements, and technical design guides, and teach associated learning sessions.
• Lead and align people who do not directly report to the position and communicate technical opinions effectively at all levels.

Benefits

• Immediate medical, dental, vision, and prescription drug coverage.
• Paid parental leave, new parent ramp-up programs, and subsidized back-up child care.
• Family-building benefits including adoption and surrogacy expense reimbursement and fertility treatments.
• Vehicle discount program for employees and family members, and management leases.
• Tuition assistance.
• Employee resource groups.
• Paid time off for individual and team community service.
• Vacation time, sick/personal time, and paid holidays, including between Christmas Eve and New Year’s Day.

What This Job Offers

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