Product Development Engineer - Heat Exchanger Core Engineer

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

This position will lead all the heat exchangers (Condenser, Radiator, CAC, WCC, Battery Chiller etc.) with expertise on design, materials (Aluminum alloy) and manufacturing processes (brazing), and laboratory analysis techniques.

• Support creation and maintenance of the Core Engineering Documents (DFMEA/SCCAF Documents, Requirements and Test Procedures, etc.)
• Support application teams in sourcing decisions, validation planning, engineering sign offs and manufacturing site reviews.
• Signoff of DV/PV/SREA/DPA for HEX Components.
• Technical Problem Solving for Launch, Recall,Quality / Field Issues..
• Understanding manufacturing process for all types of heat exchangers: tube/fin forming, stampings, injection molding, brazing and EOL leak check.
• Understand corrosion methodology for various types of heat exchangers (rolled tube, extruded tube, plate stack, etc). Able to conduct root cause analysis and work with suppliers on countermeasures and preventative actions.
• Understanding of Materials, Analysis Tools, Design and Manufacturing for HEX Components.
• Able to lead technical discussions to deliver optimized Refrigerant or Power Train Designs for use in vehicle systems.
• Must be able to work with other FORD organizations, labs, and outside suppliers to help direct solutions for issues.
• Support global applications teams with refrigerant and coolant based heat exchangers issue.
• Optimize designs for Cost reduction while maintaining quality performance.
• Interact with Refrigerant, Power Train, NVH, Controls and CAE teams.
• Collaborate with subsystem Technical Specialist within the company and with external suppliers.
• Support new technology/supplier development.
• Support strategy papers such as Modularity, Commodity Business Plan.
• Provide technical support for cost reduction ideas and quality improvements.

Minimum Requirements:

• Bachelor of Science in Mechanical or Industrial Engineering or a related field
• 3+ years of experience in HEX designs and development.
• The D&R Engineer is responsible for managing product release CAD and BOM structures, including assembly positioning and mass attribute analysis. This role also includes facilitating supplier data integration and developing CAD studies to support and drive design improvements.
• Strong DFMEA knowledge and implementation per AIAG/VDA.
• Laboratory experience in metallurgy related to heat exchangers.
• Knowledge in corrosion lab testing and material designs.
• Knowledge of materials and heat exchanger manufacturing processes (fluxing, brazing, EOL checks)
• Understanding of investigation tools – SEM, FTIR, Surface Analysis Tools, TGA.
• Key:
  • Ability to lead and align collections of people that do not directly report to this position.
  • Ability to institutionalize the key factors of thermal systems success and lessons learned through documentation (design rules, requirements, technical design guides, etc.) and to teach associated learning sessions.
  • Ability to form an opinion, communicate it effectively at all levels, and drive the company in a winning direction.

• Master of Engineering (electrical,…