Mechanical Development Engineer - Gearbox

Mechanical Development Engineer (MDE) for Differential, Gears & Shafts

Borg Warner is a global product leader in delivering innovative and sustainable mobility solutions. We are a company of innovators and independent thinkers that bring together talented employees, meaningful work and amazing technology in a unique environment. At Borg Warner, we constantly work towards our vision of a clean and energy-efficient world.

The Mechanical Development Engineer (MDE) for Differential, Gears & Shafts is responsible for the design, development and release of components that are used in conjunction with each other within an assembly to meet the overall performance requirements of a product.

The MDE works within the eDrive Engineering organization in collaboration with CAD Designers and CAE (Computer – Aided Engineering) Engineers.

The MDE must be capable of completing work requests from the Project Team Members to meet the defined program performance requirements and timing. In this role, the MDE is responsible for requesting design and analysis work from the CAD and/or CAE team members while working simultaneously with Manufacturing, Purchasing, and suppliers to receive input and to address technical issues in preparation for production launch, and during production to support cost reductions and robust improvements.

Responsibilities include:

• Develop differential, gears and shafts components to meet performance, cost, and manufacturability targets.
• Collaborates with system integration, NVH, and durability teams to optimize driveline performance.
• Support New Business Opportunity (NBO) initiatives by designing and developing mechanical systems and subsystems, including integrated drive modules (iDMs) and fully assembled eMotors, with a focus on components such as differential, gears and shafts.
• Support Value Analysis/Value Engineering (VA/VE) initiatives within application projects by identifying opportunities to optimize cost, enhance performance, and improve manufacturability.
• Demonstrate thorough knowledge of component drawing requirements for differential, gears, and shafts, including dimensional tolerances, application of GD&T, and utilization in stack-up calculations to ensure design integrity and assembly compatibility.
• Conduct engineering analyses and calculations on components and sub‑systems, and present technical rationale to program teams to support design decisions and ensure compliance with performance requirements.
• Issue CAE requests and provide technical direction for system and component analyses to support design validation and optimization.
• Create and maintain component and sub-system Design Failure Mode and Effects Analyses (DFMEAs) and utilize them to define and manage Special Characteristics that ensure product reliability and compliance with program requirements.
• Create design work orders and provide direction to CAD resources to develop product designs; review, approve, and release engineering drawings to support program requirements.
• Utilize Siemens Teamcenter to manage engineering drawings, maintain Bill of Materials (BOM) structures, and oversee 3D model development to ensure accuracy, consistency, and compliance with program standards.
• Create Advanced Design Verification Plan and Report (ADVP&R) to validate the component performance, and issue laboratory work orders to direct technicians in conducting component testing.
• Analyse mechanical components for wear and durability to ensure compliance with performance and reliability requirements.
• Prepare test reports documenting outcomes of component and system validation activities.
• Support vehicle-level integration and troubleshooting during development and launch.
• Support tooling development and process validation.
• Act as technical liaison with Purchasing, suppliers, and Supplier Development Engineers for new component projects involving differential, gears, and shafts.
• Establish technical requirements for supplier selection and contribute to the decision-making process.
• Willingness and ability to travel locally to manufacturing sites, with a primary focus on gaining hands-on knowledge of the assembly line and providing support for component…