Senior Engine Design Engineer

FEV North America•Auburn Hills, MI

About The Position

The Senior Engine Design Engineer leads the design, development, validation, and production release of internal combustion engine (ICE) and/or hybrid powertrain mechanical components and subsystems. This role is responsible for delivering robust designs that meet performance, durability, packaging, cost, manufacturability, and quality targets. The engineer serves as a technical leader, mentoring others, driving cross-functional execution, and owning complex design problems from concept through production launch.

Requirements

Must be a US Citizen or Permanent Resident
Bachelor’s degree in Mechanical Engineering or related field (Master’s preferred)
5+ years of engine or powertrain hardware design experience (or equivalent advanced development experience)
Strong proficiency with 3D CAD (e.g., CATIA, NX, Creo, SolidWorks) and GD&T
Demonstrated experience taking designs through prototype - validation - production release
Solid understanding of materials & manufacturing (cast iron/aluminum, steels, heat treat, surface finishes), mechanical design fundamentals (fatigue, bolted joints, sealing, tribology, thermal expansion), design for quality and reliability (PFMEA, DFMEA, control plans, tolerance stack-up)
Experience with engineering change management and BOM/configuration control
Strong knowledge of engine mechanical design principles, CAE methods, and manufacturing processes
Excellent communication, leadership, and organizational skills
Ability to participate in defense and export-controlled projects without special licensing

Nice To Haves

Prior experience working with global OEMs or engineering service providers
Background in combustion engines for industrial applications (marine, rail, power generation)
Experience with advanced tools (3D CAD, CAE, 1D simulation, PLM systems)
Understanding of systems engineering methodologies
Familiarity with APQP/PPAP, supplier development, and launch support

Responsibilities

Own end-to-end design responsibility for engine hardware (e.g., block, head, valvetrain, crank train, piston/rod, lubrication, cooling, induction/exhaust interfaces, mounting/structures, covers, brackets, accessory drives)
Manage creation and refinement of 3D CAD models, assemblies, and 2D drawings
Create and refine GD&T, tolerancing strategy, and fit/function requirements
Perform concept trade studies and lead design decisions considering performance, cost, risk, packaging, NVH, durability, and serviceability
Drive design standards and best practices, ensuring compliance with internal standards, industry norms, and safety requirements
Develop design solutions guided by FEA/CFD inputs and physical requirements (stress, fatigue, thermal distortion, modal behavior, sealing, wear)
Define and review test plans (DV/PV, durability, thermal, sealing, corrosion, vibration) and translate test findings into design actions
Lead root cause investigations for failures (fracture, fatigue, scuffing, oil aeration, overheating, bolt loosening, gasket leaks) using structured methods
Own component design verification reports and engineering signoffs (design release readiness, deviation approvals, change control justification)
Ensure component designs integrate with packaging constraints and system interfaces (mounting, accessory alignment, sealing, routing)
Support prototype builds, teardowns, plant trials, and field issue triage
Plan and execute work packages: schedule, risk register, technical deliverables, and design reviews
Lead technical design reviews, manage engineering changes, and ensure clean BOM structure and configuration control
Mentor junior engineers and designers; review their work for correctness and maturity
Contribute to strategic technology roadmaps