Senior Engine Design Engineer

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.

Product & Component Design Leadership

• 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

Engineering Analysis & Validation

• 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)

Systems Integration & Cross-Functional Coordination

• 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

Project Execution & Technical Leadership

• 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

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

Preferred Qualifications:

• 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

Equal opportunity employer as to all protected groups, including protected veterans and individuals with disabilities