Junior Mechanical Design Engineer - ERS

Job Title:

Junior Mechanical Design Engineer - ERS

Location:

Concord, NC
Company: GM Performance Power Units (GM PPU)
Drive the Future of Formula 1 with GM PPU!

We’re on the hunt for a detail-oriented Junior Mechanical Design Engineer to join our ERS (Energy Recovery System) Team in Concord, NC. In this high-stakes, high-impact role, you’ll support the design and development of critical mechanical and electromechanical components for our Formula 1 hybrid powertrain, including structural optimization and mechanical integration for the MGU (e-motor), CU‑K (inverter and DC‑DC), and ES (battery).
Develop precise 3D models, technical drawings, and simulations using advanced CAD/CAE tools to ensure mechanical integrity under extreme racing conditions. Collaborate with cross‑functional teams in electrical controls, thermal management, and manufacturing to optimize ERS packaging, mounting, and system integration while adhering to FIA technical regulations. Participate in prototype reviews, testing, and iterative improvements to deliver reliable, high‑performance mechanical solutions that enable winning designs.

• Assist in the detailed design and development of mechanical components for the ERS, including packaging, mounting, and integration with power unit systems.
• Support senior engineers in preparing engineering models, drawings, and simulations to validate mechanical design integrity.
• Collaborate with cross‑functional teams such as electrical controls, thermal management, and manufacturing to optimize design feasibility and performance.
• Participate in prototype build reviews, testing, and validation to ensure components meet functional and durability targets.
• Contribute to maintaining documentation and compliance with FIA technical regulations relating to ERS components.
• Help identify design improvements through problem‑solving and testing feedback.
• Stay updated on emerging engineering technologies and tools relevant to F1 ERS development.

• Bachelor’s degree in Mechanical Engineering or a closely related discipline.
• Strong foundation in mechanical design principles including statics, dynamics, materials science, and stress analysis.
• Proficiency in parametric 3D CAD software such as CATIA, NX, or Solid Works for creating models and technical drawings.
• Proficiency in GD&T (ASME Y14.5) for engineering drawings and tolerancing.
• Experience with vibration, fatigue, and dynamic analysis for high‑performance components.

• Familiarity with F1 technical regulations, particularly those governing ERS components and power unit integration.
• Experience with CAE/FEA tools like ANSYS for thermal and structural simulations in high‑performance environments.
• Hands‑on experience in motor sport prototyping, testing processes, or cross‑functional collaboration in hybrid powertrain systems; preference for Formula SAE or Formula Student program participants.
• Knowledge of advanced materials (e.g., composites, lightweight alloys) and manufacturing processes like composite lay‑up, CNC milling/turning, and additive manufacturing (AM).
• Knowledge of Design for Manufacture/Assembly (DFM/DFA) principles and tooling/jig design for motor sport prototyping.
• Understanding of engineering drawing standards and quality management systems relevant to motor sport.
• Familiarity with PLM systems (e.g., Teamcenter) for version control and collaborative design workflows.

• Strong analytical mindset with a passion for problem‑solving and continuous improvement.
• Excellent attention to detail and commitment to maintaining high quality and precision in all work.
• Eagerness to learn quickly and adapt in a fast‑paced, high‑pressure environment.
• Effective communication and teamwork skills to collaborate with multidisciplinary groups.
• Self‑motivated with a proactive approach to taking ownership of tasks and delivering results.

Drive the Future of Motorsport with GM PPU!
At GM PPU, we’re not just building power units — we’re shaping the future of Formula 1 technology. Our culture of collaboration fuels creativity and innovation, empowering you to make a real impact on the track. Every idea counts, every breakthrough…