Product Engineer Thermal

Design for Manufacture & Assembly (DFM/DFA): Develop designs optimized for their manufacturing processes (injection molding, brazing, stamping, extrusion, machining) and for high-volume assembly, working with full service and build to print suppliers on tooling and process feasibility to balance cost, mass, and quality. Cross-Functional Collaboration: Work closely with the system and subsystem engineers (who own performance targets), Controls Engineers (for actuator/valve strategy), test engineers (for validation), and suppliers (for tooling and build), supporting design reviews and readiness gates through launch.

Key Responsibilities:
You will lead the mechanical design of thermal system hardware across one or more subsystems, translating performance and packaging requirements into detailed, manufacturable designs.

• Component & Assembly Design: Design thermal hardware across coolant, refrigeration, and HVAC/climate subsystems in 3D CAD from concept through production release.
• System Packaging & Routing: Package and route thermal hardware through the vehicle, resolving space, interface, and clearance constraints with adjacent systems (battery, drive unit, power electronics, IP, chassis, and body) and coordinating shared interfaces across subsystems.
• Performance-Driven Design: Translate thermal, hydraulic, and refrigerant performance targets from the system and subsystem engineers into physical geometry — flow paths, sealing, mounting, and heat-exchanger placement — that meets thermal, pressure, and flow requirements.
• Design for Manufacture & Assembly (DFM/DFA): Develop designs optimized for their manufacturing processes (injection molding, brazing, stamping, extrusion, machining) and for high-volume assembly, working with full service and build to print suppliers on tooling and process feasibility to balance cost, mass, and quality.
• Tolerance & GD&T: Apply geometric dimensioning and tolerancing, perform tolerance stack-up analysis, and define critical dimensions to ensure fit, sealing, and function across the production range and across mating subsystems.
• Design Analysis & Robustness: Support structural, flow, thermal, and durability analysis (CFD/FEA in partnership with analysis teams), and use DFMEA to identify and mitigate various failure modes.
• Engineering Documentation: Create and release detailed part and assembly drawings, manage engineering changes, and maintain CAD data and bills of materials through the product development process.
• Cross-Functional Collaboration: Work closely with the system and subsystem engineers (who own performance targets), Controls Engineers (for actuator/valve strategy), test engineers (for validation), and suppliers (for tooling and build), supporting design reviews and readiness gates through launch.

Skills Required:
Mechanical Engineering, CAD Design, Heat Exchange, Product Design

Experience Required:

• Bachelor's degree in Mechanical Engineering or a related discipline.
• 3+ years of experience in mechanical design of automotive components or systems.
• Proficiency in 3D CAD (CATIA, NX, or 3DEXPERIENCE) for part and assembly modeling and detailing.
• Working knowledge of GD&T and tolerance stack-up analysis.
• Solid understanding of design for manufacture and assembly across multiple processes (e.g., molding, brazing, stamping).
• Familiarity with heat transfer, fluid dynamics, and pressure-system fundamentals as they apply to thermal hardware.

Experience Preferred:

• Master's degree in a relevant engineering discipline.
• Direct experience designing thermal hardware — coolant loops, refrigeration/heat-pump circuits, heat exchangers, or HVAC units.
• Experience with EV thermal management systems (battery, drive unit, power electronics, and cabin cooling/heating).
• Familiarity with refrigeration and HVAC systems.
• Experience with actuator- and valve-driven hardware and control interfaces.
• Experience with DFMEA, DVP&R, and the release/change-management process for production parts.

Education Required:
Bachelor's Degree

Education Preferred:
Master's Degree