Senior Engineer, Whole Vehicle Thermal Testing

Scout Motors • Novi, MI

4h • $120,000 - $145,000 • Onsite

About The Position

The Senior Thermal Systems Design Release Engineer (DRE) serves as the technical leader and end to end owner of advanced thermal management components and subsystems across multiple vehicle programs. This role is responsible for leading the design, development, validation, release, and lifecycle support of complex thermal hardware including cooling modules, HVAC systems, refrigerant circuits, battery thermal systems, pumps, valves, heat exchangers, and related fluid handling components.
The senior DRE ensures that all thermal subsystems meet or exceed OEM performance, durability, cost, quality, manufacturing, and timing targets from program initiation through Job 1 and into post launch operations. This role requires deep technical capability, cross functional leadership, supplier management expertise, and the ability to resolve complex system level issues.

Requirements

• Bachelor’s degree in Mechanical Engineering, Automotive Engineering, or related discipline.
• 6+ years of experience in automotive thermal systems or closely related hardware.
• Deep understanding of heat transfer, fluid dynamics, coolant systems, refrigerant circuits, and thermal system integration.
• Expertise with OEM CAD and PLM systems and experience leading engineering releases through full vehicle development cycles.
• Demonstrated ability to lead complex design efforts and resolve system level issues in cross functional environments.

Nice To Haves

• Experience with EV thermal architectures, integrated cooling systems, and high voltage thermal components.
• Strong knowledge of APQP, PPAP, DFMEA, DVP&R, and quality systems.
• Familiarity with manufacturing processes for heat exchangers, pumps, valves, hoses, and molded plastic/metal components.
• Proven track record of leading supplier development, managing global supply chains, and supporting launch activities.
• Advanced problem-solving skills including structured root cause analysis, system simulations, and data driven decision making.

Responsibilities

• Thermal System Leadership & Technical Ownership
• Serve as the senior engineering authority and “single point of responsibility” for assigned thermal systems within one or more vehicle platforms.
• Translate vehicle level thermal, energy, and performance targets into detailed component level technical requirements and specifications.
• Lead system integration efforts to ensure compatibility with vehicle controls, electrical architecture, software interfaces, and packaging constraints.
• Provide technical mentorship to junior DREs and influence cross functional engineering decisions related to thermal architecture.
• Advanced OEM Design & Release Execution
• Direct the creation, evolution, and approval of CAD models, drawings, specifications, and documentation within the PLM environment.
• Own part numbering strategy, BOM structure, and engineering releases for all gateway milestones across multiple vehicle programs.
• Lead high level design reviews, trade off discussions, and technical forums with product development, controls, electrical, manufacturing, and program leadership.
• Drive early issue identification and resolution through advanced analytical tools and system modeling.
• Supplier & Sourcing Leadership
• Serve as the chief technical interface to global suppliers, ensuring alignment on requirements, performance expectations, timing, and quality.
• Review, challenge, and approve supplier engineering documentation including DFMEA, DV plans, tolerance stacks, and material/process specifications.
• Partner with Purchasing to evaluate sourcing strategies, review commercial proposals, and assess supplier technical readiness.
• Lead supplier launch readiness activities including tooling kickoff, PPAP validation, and manufacturing capability audits.
• Validation Strategy & Vehicle Build Support
• Develop, own, and execute comprehensive DVP&R plans for thermal components and subsystems.
• Provide on-site support for prototype, mule, VFF, and production builds, lead issue triage, root cause analysis, and corrective actions.
• Lead technical support for thermal testing campaigns including environmental chambers, weather events, dynamometer testing, and wind tunnel evaluations.
• Collaborate with Vehicle Integration and Controls teams to ensure system performance meets real world and regulatory requirements.
• Quality, Manufacturing & Launch Excellence
• Coordinate closely with Manufacturing Engineering to ensure that component designs meet plant requirements and process capabilities.
• Lead and support PFMEA reviews, control plan development, and PPAP documentation for thermal systems.
• Drive resolution of launch issues including leaks, noise and vibration concerns, flow restrictions, contamination, and supplier non conformances.
• Implement lessons learned and design optimizations to ensure continuous improvement across vehicle programs.

Benefits

• Medical, dental, vision and income protection plans
• 401(k) program with:
• An employer match and immediate vesting
• 20 days planned PTO, as accrued
• 40 hours of unplanned PTO and 14 company or floating holidays, annually
• Up to 16 weeks of paid parental leave for biological and adoptive parents of all genders
• Paid leave for circumstances related to bereavement, jury duty, voting time, or military leave

What This Job Offers

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