Vehicle Integration Engineer

Job Description

Job Description

Position Summary

Optimal EV is seeking a hands-on Vehicle Integration & Validation Engineer to support the development, integration, testing, and validation of complete electric vehicle platforms.

This role is not limited to electrical systems or test execution. The engineer will work directly on prototype and production-intent vehicles across mechanical, electrical, controls, charging, thermal, chassis, and vehicle-level systems to ensure the complete vehicle is properly designed, assembled, integrated, validated, and ready for production release.

The ideal candidate is comfortable working both at a computer and on the shop floor. This person should be able to inspect vehicles, install and remove components, take measurements, identify fit-up and tolerance issues, troubleshoot mechanical and electrical problems, develop test procedures, perform DFMEA, and drive cross-functional issues to closure.

The engineer will play an important role in identifying design and integration problems before they become production or field issues .

Key Responsibilities

Vehicle Integration & Hands-On Testing

• Plan and execute complete vehicle integration and validation testing.
• Work directly on prototype and production-intent vehicles to identify and troubleshoot integration issues.
• Support prototype builds, vehicle modifications, instrumentation, component installation, and engineering rework.
• Perform hands-on inspection, measurement, troubleshooting, and functional testing of vehicle systems.
• Use basic hand tools, measurement tools, electrical test equipment, and vehicle diagnostic equipment.
• Identify issues related to component installation, routing, accessibility, interference, clearances, and serviceability.
• Support vehicle teardown and inspection when required for root-cause investigation.

Mechanical & Assembly Validation

Validate mechanical design and assembly conditions including:

• Chassis and suspension
• Steering and braking
• Powertrain mounting and driveline components
• Mechanical brackets and structural mounting
• Battery, PDU, charger, cooling, and electrical component mounting
• Hose, cable, and harness routing
• Fasteners, torque requirements, and retention methods
• Component clearances and interference
• Assembly sequence and installation feasibility
• Fit, alignment, and interface between mating components
• Service access and component replacement
• Noise, vibration, looseness, and mechanical durability

Perform dimensional and tolerance validation to ensure components can be consistently assembled within the intended vehicle configuration.

Support activities such as:

• Critical dimension measurement
• Tolerance stack-up review
• Gap and clearance verification
• Hole and mounting-point alignment
• Bracket and interface validation
• Harness and hose routing clearance
• Suspension and moving-component clearance
• Build variation evaluation
• Production assembly validation

Work with Design Engineering and Production to identify tolerance, fit-up, or assembly problems and recommend design improvements.

DFMEA & Design Risk Assessment

• Develop and maintain Design Failure Mode and Effects Analysis (DFMEA) for vehicle-level systems and major engineering changes.
• Participate in cross-functional DFMEA reviews with Mechanical, Electrical, Controls, Manufacturing, Quality, and Service teams.
• Identify potential failure modes based on prototype builds, testing, manufacturing experience, and field issues.
• Ensure high-risk DFMEA items are addressed through design improvements, testing, or additional controls.
• Connect DFMEA risks to validation requirements and test plans.
• Update DFMEA based on validation results, design changes, production issues, and field experience.
• Support PFMEA and manufacturing risk reviews when vehicle design directly affects assembly or production processes.

Vehicle System Validation

Validate mechanical and electrical vehicle systems including:

• Chassis and suspension
• Steering and braking
• Powertrain and drivability
• Regenerative braking
• Mechanical mounting and component installation
• High-voltage and low-voltage electrical systems
• Vehicle controls and software functions
• Thermal management and cooling systems
• Charging and EVCC functionality
• CAN communication and diagnostics
• Body and auxiliary systems

Vehicle Testing

• Perform road testing, functional testing, durability testing, and system-level validation.
• Evaluate vehicle performance, drivability, braking behavior, noise, vibration, thermal performance, and overall vehicle operation.
• Perform environmental, load, endurance, and abuse testing where applicable.
• Develop test plans, test procedures, acceptance criteria, and validation reports.
• Define measurable pass/fail criteria before testing.
• Perform regression testing after software, electrical, mechanical, or component changes.
• Confirm corrective actions through physical testing rather than relying only on design review.

Engineering Change & Release Validation

• Support validation of new vehicle platforms and major engineering changes.
• Review engineering changes for potential vehicle-level integration risks.
• Determine required validation for mechanical, electrical, software, and system changes.
• Confirm that required testing is completed before production release.
• Support engineering release decisions with documented validation evidence.
• Ensure major design changes have appropriate DFMEA review and regression testing.
• Maintain traceability between engineering changes, identified risks, test requirements, and validation results.

EV & Charging Validation

• Support development and validation of the 700 V architecture and future vehicle platforms.
• Test high-voltage vehicle functionality and integration.
• Test charging functionality using AC chargers, DC fast chargers, and charging test equipment.
• Validate EVCC operation and charging interoperability.
• Support troubleshooting of charging communication and vehicle/charger integration issues.
• Support testing related to future V2G functionality where applicable.

Data Acquisition & Diagnostics

• Collect and analyze CAN logs, measurement data, and vehicle performance data.
• Use CAN and diagnostic tools to troubleshoot vehicle-level issues.
• Reproduce production and field issues and lead or support root-cause investigations.
• Correlate physical vehicle behavior with CAN data, electrical measurements, and mechanical inspection.
• Document test conditions, results, failures, root causes, and corrective actions.

Cross-Functional Engineering Support

• Coordinate with Mechanical, Electrical, Controls, Production, Quality, Service, and Supply Chain teams to resolve vehicle-level issues.
• Work closely with production technicians, supervisors, and vehicle builders to understand assembly and integration problems.
• Incorporate feedback from production personnel into engineering problem solving and design improvements.
• Work with suppliers to validate components and integrated vehicle systems.
• Support Quality and Service investigations for production and field failures.
• Drive issues to closure rather than allowing problems to remain between engineering departments.

Test Facility Support

• Support development and operation of vehicle test equipment and the Plymouth R&D test facility.
• Assist with test fixtures, instrumentation, data-acquisition equipment, charging equipment, and vehicle preparation.
• Help develop repeatable company-level vehicle validation methods and procedures.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Automotive Engineering, Mechatronics, or related field.
• Experience with automotive, commercial vehicle, electric vehicle, or similar complex electromechanical product development.
• Strong hands-on mechanical and electrical troubleshooting ability .
• Comfortable working directly on vehicles in a shop, prototype, or manufacturing environment.
• Understanding of vehicle systems including chassis, powertrain, thermal, electrical, and controls.
• Ability to read mechanical drawings, electrical schematics, wiring diagrams, and technical specifications.
• Understanding of mechanical tolerances, fit, clearances, mounting, and assembly principles.
• Experience using measurement equipment such as calipers, torque tools, multimeters, and other engineering test equipment.
• Familiarity with CAN communication and vehicle diagnostics.
• Experience developing and executing engineering validation tests.
• Strong root-cause analysis and problem-solving skills.
• Strong documentation and technical communication skills.
• Ability to work across multiple engineering disciplines and take ownership of vehicle-level issues.

Preferred Qualifications

• Experience with electric or commercial vehicles.
• Experience with prototype vehicle builds and vehicle-level validation.
• Experience performing or supporting DFMEA .
• Familiarity with DVP&R or similar design verification and validation processes.
• Experience with dimensional inspection, tolerance stack-up, GD&T, or assembly validation.
• Familiarity with Design for Manufacturing and Assembly (DFMA).
• Experience troubleshooting component fit-up, mounting, interference, or tolerance issues.
• Familiarity with suspension, braking, steering, chassis, structural mounting, and thermal systems.
• Experience with CAN, CANalyzer, CANoe, MATLAB, or similar tools.
• Familiarity with MATLAB/Simulink.
• Knowledge of high-voltage EV systems.
• Experience with EV charging systems and charging communication protocols.
• Familiarity with UDS diagnostics and DTC troubleshooting.
• Experience with durability, road, environmental, or vehicle performance testing.
• Experience supporting production launch or resolving manufacturing issues.
• Familiarity with engineering change and product release processes.

What Success Looks Like

• The engineer spends meaningful time working directly with vehicles , not only reviewing data or preparing documentation.
• Mechanical, electrical, software, controls, and thermal systems are validated together as a complete vehicle.
• Components are not only correctly designed on CAD but are proven to fit, assemble, operate, and survive on the actual vehicle .
• Tolerance, clearance, routing, mounting, and assembly problems are identified before production release.
• Potential design failures are systematically identified through DFMEA and addressed through design or validation.
• Prototype builds continuously improve the design instead of repeatedly encountering the same issues.
• Integration problems are identified during engineering development rather than during production or customer operation.
• Every major engineering change has clear validation requirements and documented results before release.
• Prototype vehicles progress efficiently from build to test to production-ready status.
• Production feedback is incorporated into engineering decisions.
• Cross-functional issues are driven to closure instead of remaining between engineering departments.
• Optimal EV develops a consistent and repeatable process to confirm that a vehicle is designed correctly, can be assembled correctly, and is truly ready for production .