Product Design Engineer – ADAS Radar Mounting Solutions

Job Description

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world — together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves?

In this position we are seeking a seasoned Mechanical Design Engineer with expertise in structural plastic and steel component design to lead the development of radar mounting solutions for global Ford vehicle lineups. You will ensure that these critical ADAS components are packaged securely, meet stringent vibration requirements, and maintain precise alignment throughout the vehicle's lifecycle.

• Lead Product Design:
  Own the end‑to‑end design of radar brackets or other mounting interface using CATIA V6/V5, moving from initial concept through to SOP (Start of Production).
• Material Selection:
  Determine the best material applications (e.g., glass‑filled polymers, stamped steel) based on weight, cost, durability and performance over the life of the product.
• Structural Analysis:
  Perform FEA (Finite Element Analysis) to predict modal frequencies and vibration targets to ensure the bracket doesn't resonate with engine or road frequencies and withstand long‑term “Creep” and heavy‑duty life cycles.
• Advanced GD&T:
  Apply advanced Geometric Dimensioning and Tolerancing to ensure sensor alignment remains within the required degrees from vehicle centerline.
• Statistical Knowledge:
  Utilize Design for Six Sigma (DFSS) principals to conduct complex 3D tolerance stack‑ups. This includes managing Critical‑to‑Quality (CTQ) dimensional capability metrics (e.g., SPC and PIST) and defining gauge expectations to ensure high‑volume production parts meet strict tolerances.
• Cross‑Functional
  
  Collaboration:
  
  Partner with radar supplier and ADAS core teams to apply performance/functional requirements to the bracket design considerations.
• Tooling & DFM:
  Lead Tooling Design Reviews (TDR) with injection molding suppliers. Drive optimization of gate locations, parting lines, and draft angles to minimize warpage—critical for maintaining radar boresight accuracy.
• Supplier Technical Management (Build‑to‑Print):
  Act as the primary technical lead for manufacturing partners. Manage the hand‑off of engineering CAD data and drawings to suppliers and ensure they execute the design to exact specifications.
• Manufacturing Readiness & PPAP:
  Facilitate and oversee the Production Part Approval Process (PPAP). Review supplier submissions, including dimensional results, control plans, and PFMEAs, to ensure the manufacturing process is capable of producing parts that meet design intent.
• Radar Performance Integrity:
  Ensure the bracket maintains precise boresight alignment and limits “sensor jitter” to within specified tolerances.
• Interface & Packaging Management:
  Collaborate with Studio (Styling) and Body Engineering to package sensors behind fascias or grilles. Ensure “keep‑out” zones and field of view (FOV) requirements are met. Account for harness routing, connector “click‑space,” and strain relief to support long‑term mounting durability.
• Validation Oversight:
  Define and lead DV/PV (Design Verification/Production Verification) testing with buy‑in from radar core stakeholders. Ensure parts pass all environmental, thermal, and mechanical shock tests required for the segment.

You’ll have:

• Bachelor’s Degree in Mechanical Engineering or related field of study.
• 5+ years of experience in automotive mechanical design, specifically with structural injection‑molded plastics and steel components.
• Strong understanding of injection molding and sheet metal stamping processes.
• Expert level CAD experience in modeling software.
• Experience with the APQP/PPAP process and working with Tier 1/Tier 2 suppliers in a build‑to‑print environment.
• Strong understanding of GD&T (ASME Y14.5).
• Proven track record of managing tooling timelines and resolving manufacturing non‑conformances.
• Knowledge of and experience performance FEA.

Even better, you may have:

• Master’s Degree in Mechanical Engineering or related field of study.
• 10+ years of experience in automotive mechanical design, specifically with…