Sheet Metal Designer

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life‑saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more.

As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing.

When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow.

You will be a key contributor within a world‑class automotive body structures engineering team, responsible for the development and delivery of sheet metal components and assemblies. This role focuses on detail design, structural feasibility, and launch execution, working closely with body engineering, manufacturing, stamping suppliers, and cross‑functional program teams to deliver production‑ready sheet metal solutions from concept through SOP.

• Lead or support the engineering, packaging, release, and launch of body sheet metal components including closures, body‑in‑white structural members, reinforcements, brackets, and attachment systems across the UEV vehicle architecture.
• Translate body design and structural intent into production‑feasible, stampable sheet metal designs that meet functional, dimensional, and manufacturing requirements.
• Define and own GD&T datum and locating strategy for sheet metal assemblies; perform tolerance stack‑up and dimensional variation analysis to ensure fit, function, and assembly compliance.
• Manage component‑level DFMEA, DVPR, SCCAF, boundary diagrams, and robustness checklists through design and release milestones.
• Work cross‑functionally with body structures, closures, chassis, manufacturing engineering, purchasing, and program teams to prioritize overall vehicle performance and timing.
• Collaborate closely with stamping and forming suppliers to ensure tooling feasibility, steel‑safe progression, blank optimization, and on‑time program delivery.
• Perform and support DFM assessments, formability analysis, spring back prediction, and weld/join feasibility reviews for sheet metal assemblies.
• Define material specifications including grade, thickness, coating, and surface finish requirements; support material substitution trade studies for mass and cost optimization.
• Support prototype builds, body buck reviews, and dimensional quality resolution through gauge studies and closed‑loop corrective action.
• Maintain PLM/BOM accuracy and manage engineering documentation through Ford's product development system.
• Apply and continuously improve engineering tools, methods, and best practices to support accelerated development on a fast‑paced EV startup‑style program.

• 4+ years’ experience in automotive sheet metal design and release engineering (body structures, closures, BIW reinforcements, brackets, etc.).
• Strong understanding of sheet metal manufacturing processes including stamping, progressive die, roll forming, hydro forming, and spot/laser welding.
• Proficiency in CATIA V5/V6 or equivalent CAD tools; working knowledge of GD&T per ASME Y14.5 and tolerance analysis methods.
• Experience supporting vehicle or product launches, including supplier tooling sign‑off, first article inspection, and manufacturing readiness reviews.
• Familiarity with DFMEA, DVPR, and structured quality documentation processes.

• Ownership of at least one full program lifecycle from concept through SOP in a body structures or closures role.
• Experience in a fast‑paced OEM or EV startup environment with compressed development timelines.
• Deep knowledge of high‑strength and advanced high‑strength steel (AHSS/UHSS) selection, formability limits, and joining strategies for EV body architecture.
• Familiarity with…