Electrical Systems Design Release Engineer

Senior Design Release Engineer (DRE) — Electrical Systems

Department: Electrical Systems

Reports to: Director, Electrical Systems · Employment Type: Full-time/On-site

Role Overview

Senior Design Release Engineer (DRE) manages the design, release, and lifecycle of electrical/electro-mechanical modules and Off-The-Shelf (OTS) components. This role is ideal for an experienced engineer who thrives in a fast-paced start-up environment, where no job is too small, and where leadership means owning the details — from CAD and BOM accuracy to strategic design decisions and supplier execution.

They will package circuit boards, integrate internal harnessing (LV/HV), drive enclosure tooling, manage change processes, support hands-on prototype builds, and deliver to program milestones. They are both a technical expert and a practical problem-solver who jumps in wherever needed to ensure successful execution.

Key Responsibilities

Product Ownership & Release

• Serve as the technical lead and single point of accountability for assigned modules, from concept through SOP and sustaining.
• Manage detailed part-level execution while always considering system-level impact
• Own complete product definition including CAD, engineering requirements, drawings, GD&T, materials and sealing strategy
• Support prototype and pilot builds hands-on, resolving issues at the bench or on the line as needed.
• Prepare and release assembly documentation for box build assemblies (BBA)

PCB & Module Packaging

• Lead packaging of PCBs into enclosures, including connector layouts, stack-ups, thermal management, sealing, and EMC control.
• Own selection, qualification, and integration of off-the-shelf components (connectors, vents, fasteners, displays, grommets, thermal parts).
• Perform DMU/clash analysis and ensure manufacturability, serviceability, and robustness.

Harnessing Inside Enclosures or Box Builds (LV & HV)

• Design and integrate internal harnessing for both low-voltage and high-voltage systems within enclosures or BBAs
• Establish routing paths that meet electrical safety, mechanical constraints, bend radius, creepage/clearance, thermal considerations, and EMC requirements.
• Specify fixation methods (clips, cable channels, strain-relief points, clamps, grommet routing, tie-downs).
• Validate harness integration through:
• Fit checks and tolerance simulations
• Vibration/robustness assessments
• Thermal exposure and derating checks
• HV safety evaluations
• Environmental simulations

Enclosure Design & Tooling

• Own enclosure design for injection molding, die casting, sheet metal, machining, and rapid-prototype builds.
• Work with a vendor to define tooling strategy (class, gating, parting line, draft, T0/T1/Tn expectations).
• Drive DFM/DFA reviews, tooling kickoff, and sample evaluation with suppliers.
• Resolve tooling issues quickly, pragmatically, and collaboratively.

CATIA / CAD / PLM

• Create and manage high-quality CATIA V6/3DEXPERIENCE models and assemblies.
• Produce engineering drawings using GD&T (ASME Y14.5) and perform tolerance stack-ups.
• Maintain EBOM configuration in PLM systems with high accuracy and discipline.

BOM Ownership

• Own the Engineering BOM end-to-end:
• Part number creation and revision control
• Alternates and AML/AVL
• Effectivity management
• Completeness across subassemblies including consumables
• Ensure clean alignment between EBOM ↔ MBOM and support service BOM development.
• Fix BOM issues at a tactical level if needed — no job too small.

Change Management (ECR/ECO)

• Lead creation and implementation of ECR/ECOs, with clear problem statements, justification, impact analysis, and effectivity planning.
• Drive cross-functional approvals and ensure traceability to requirements, validation, and supplier inputs.
• Streamline ECO cycle time through proactive documentation and planning.

Program & Timeline Management

• Own schedules for assigned components, identifying dependencies, risks, and mitigation plans.
• Work with and manage contractors for short term projects
• Drive progress toward key milestones (Design Freeze, DV, PV, Tooling, PPAP, SOP).
• Work closely with suppliers on development, timing, and PPAP readiness.
• Step in hands-on to remove blockers in a start-up environment.

Hands-On Prototype Build Support

• Work directly with technicians and engineering teams on bench builds, mock-ups, prototype assemblies, and in-vehicle installations.
• Assemble PCB modules, install OTS components, test harness routing, fit internal harnesses, torque fasteners, and validate sealing.
• Run physical clearance checks, thermal interface installation, vent/gasket placements, and mechanical fastener operations.
• Document issues, root causes, and feed detailed learnings quickly back into design, BOM, and ECO processes.
• Support rapid iteration in a start-up environment where speed, flexibility, and hands-on problem-solving are essential.

Minimum Qualifications

• B.S. in Mechanical Engineering, Mechatronics, Electrical Engineering, or related field.
• 7+ years in DRE/Product Engineering in automotive or adjacent industries.
• Deep experience with CATIA and GD&T.
• Proven ownership of BOMs and ECOs in PLM systems.
• Expertise in PCB packaging, OTS integration, and enclosure design.
• Experience designing and routing LV/HV internal harnessing.
• Strong cross-functional leadership and the ability to execute hands-on when needed.

Preferred Qualifications

• Experience with ENOVIA/3DX
• Familiarity with APQP/PPAP, DV/PV testing, and automotive environmental standards.
• Strong understanding of reliability engineering.
• HV safety experience (creep/clearance, insulation, sealing).
• Supplier tooling oversight and rapid-iteration prototyping experience.
• Start-up experience strongly preferred.

Tools & Systems

• CATIA V5/V6/3DX
• PLM: 3DEXPERIENCE/ENOVIA
• MS Project / Smartsheet / Jira / Confluence
• Microsoft 365