Sr. Mechanical Design Engineer

Job Description:

Under the direction of the Director, this role is responsible for the design, implementation, and optimization of advanced mechanical structures, with a strong focus on software-defined mobility solutions for the automotive industry.

Design and develop robust mechanical structures for ECU systems, ensuring accurate thermal management, and protection against environmental factors (e.g., vibration, shock, thermal cycling or sealing).

Generate new concepts and validate them through experiments and engineering analysis.

Collaborate closely with hardware engineering teams to optimize ECU housing designs, ensuring appropriate integration with electronic components, PCBs, connectors and wiring harnesses.

Perform detailed 3D modeling and drafting using Solidworks CAD software.

Conduct comprehensive tolerance stack-up analyses and apply GD&T principles to ensure manufacturing feasibility, functionality, and assembly accuracy.

Develop and oversee mechanical testing protocols, including shock, vibration, and thermal cycling, to confirm system robustness and reliability.

Evaluate and select appropriate materials and manufacturing processes (e.g., injection molding, die-casting, sheet metal stamping) to optimize quality, performance, manufacturability, and cost-efficiency.

Collaborate with suppliers and internal production teams to ensure designs are production-ready and support smooth transition into high-volume manufacturing.

Participate with Astemo US & Japan Design Engineering organizations in the original design / existing design improvements and performance validation of ECUs.

Prepare comprehensive technical documentation, including Bill of Materials (BOM), detailed component and assembly drawings, and mechanical design specifications.

Participate actively in cross-functional meetings, effectively communicating design progress, risks, and improvement recommendations.

Follow the company’s quality policies and procedures.

Uphold safety standards and environmental compliance.

• At least 3 years of experience in ADAS (Advanced Driver Assistance Systems) or ECU design
• Design for thermal management with liquid cooling
• Experience with at least one mass production development project in ADAS or ECU
• Strong understanding of automotive mechanical components and production quality requirements
• Proficiency in CAD tools (e.g., Solid Works)
• CAE skills including stress, thermal, and vibration analysis
• Experience with D-FMEA, DRBFM, Tolerance Stack, GD&T
• Ability to create test plans and execute development experiments
• Strong communication and presentation skills
• Ability to work both independently and as part of a team
• Proficiency in Microsoft Office and general PC software applications
• Additionally, the ability to work independently with minimal direction is required as are strong verbal and written communication skills
• Experience with PCs and application software, such as MS Office tools is also required

Bachelor's degree in Mechanical Engineering or related field (Master’s degree preferred).

Minimum 5 years of relevant experience with a Bachelor’s degree, or 2 years with a Master’s degree.

• Ability to travel domestically and internationally as needed
• Comfortable working in a professional office, testing environments, and occasionally in manufacturing settings

Equal Opportunity Employer (EOE) – Qualified applicants will receive consideration without regard to their race, color, religion, sex, sexual orientation, gender, identity, disability, protected veteran status and national origin.

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