Design Engineer

Job Title: Design Engineer – Pennsylvania

Department: Engineering

Reports To: Lead Engineer

Position

Summary

The Design Engineer is responsible for the end-to-end mechanical design and development of vehicle-related products, components, and assemblies from concept through production support. This position combines advanced SolidWorks modeling, engineering analysis, technical documentation, prototype evaluation, and hands-on installation work. The successful candidate will collaborate with Engineering, Validation, Quality, Purchasing, Production, suppliers, and other stakeholders to deliver safe, reliable, cost-effective, and manufacturable solutions that satisfy customer requirements, internal standards, and project schedules.

Responsibilities

• Create and develop 3D models of components and assemblies in SolidWorks, translating product requirements into robust mechanical designs that address function, structural performance, manufacturability, serviceability, and ease of assembly.
• Prepare complete component and assembly drawings, including dimensions, tolerances, materials, finishes, notes, and revision information, for release to suppliers and internal manufacturing teams.
• Develop and maintain accurate bills of materials (BOMs), part lists, and associated engineering documentation throughout the product lifecycle.
• Support prototype and production builds through hands-on assembly, fit checks, troubleshooting, design adjustments, and clear communication of findings to project stakeholders.
• Remove vehicle trim and install products as needed to evaluate packaging, fit, function, accessibility, and installation requirements while following established safety and workmanship standards.
• Operate a portable 3D scanning arm within vehicle interiors to capture accurate dimensional data; process and apply scan data to support design development and verification.
• Travel occasionally, approximately three trips per year, primarily to Michigan, to support vehicle measurements, installations, validation activities, supplier coordination, or production needs.
• Provide timely technical support to Engineering, Validation, Purchasing, Quality, Production, and suppliers by clarifying design intent and resolving product or manufacturing issues.
• Perform tolerance stack-ups and structural evaluations to verify that designs meet requirements; apply finite element analysis (FEA) knowledge when appropriate.
• Use data-driven problem-solving and root-cause analysis methods to investigate failures, document conclusions, recommend corrective actions, and confirm effectiveness.
• Support engineering process improvements and company technical initiatives, including document control, design reviews, standardization, and ISO compliance activities.

Requirements

• Bachelor’s degree in Mechanical Engineering or a closely related engineering discipline from an accredited institution.
• Five to ten years of progressive design engineering or product-development experience using a solid-modeling CAD platform; demonstrated proficiency with SolidWorks is strongly preferred.
• Working knowledge of geometric dimensioning and tolerancing (GD&T), tolerance analysis, design for manufacturability (DFM), and design for assembly (DFA).
• Strong mechanical aptitude, sound engineering judgment, attention to detail, and the ability to manage multiple priorities in a deadline-driven environment with limited supervision.
• Practical experience with one or more of the following manufacturing processes, listed in order of preference:
• Sheet-metal fabrication, forming, and stamping.
• Machining, milling, and turning.
• Plastic injection molding and metal die casting.
• Painting, plating, and other finishing processes for metal and plastic components.
• Proficiency with Microsoft 365 applications, including Excel, Word, and PowerPoint, in a Windows environment.
• Strong written and verbal communication skills, including the ability to explain technical information clearly to cross-functional audiences.
• Demonstrated proficiency with common hand tools and the ability to perform careful mechanical assembly and installation work.
• Visual acuity corrected to 20/20, as needed to perform detailed inspection, measurement, installation, and computer-based design work.

Preferred

Qualifications

• Experience designing products or equipment for automotive, commercial-vehicle, public-safety, fleet, or other highly engineered applications.
• Experience with product lifecycle management (PLM), engineering change notices or orders, configuration control, and formal design-release processes.
• Familiarity with 3D scanning, point-cloud or mesh processing, reverse engineering, and converting measurement data into production-ready CAD geometry.
• Experience participating in structured design reviews, failure investigations, validation planning, supplier technical reviews, or continuous-improvement initiatives.
• Working knowledge of applicable engineering standards, quality-management systems, and ISO-controlled product-development environments.

Core Competencies:

• Technical excellence: Applies sound engineering principles, careful analysis, and disciplined documentation to produce accurate, practical designs.
• Problem solving: Identifies root causes, evaluates tradeoffs, and develops timely solutions supported by data and engineering judgment.
• Collaboration: Works constructively across departments and with suppliers, communicates design intent clearly, and incorporates stakeholder feedback appropriately.
• Planning and ownership: Organizes work, manages competing priorities, meets commitments, and escalates technical or schedule risks promptly.
• Continuous improvement: Seeks opportunities to improve product quality, design methods, standard work, documentation, and manufacturing efficiency.

Additional

Requirements

• Ability to regularly lift, carry, and move items weighing up to 25 pounds and occasionally up to 50 pounds, with or without reasonable accommodation.
• Ability to bend, reach, kneel, and work in confined vehicle-interior spaces while performing measurements, trim removal, installations, and related hands-on tasks.
• Ability to travel occasionally, including approximately three trips per year, primarily to Michigan, based on project requirements.

Work Environment – Office:

• Work is primarily performed in a professional office and engineering environment using standard computer, communication, CAD, measurement, and documentation equipment.
• The role periodically requires work in prototype, manufacturing, production, supplier, or vehicle-installation areas where noise, moving equipment, tools, and other industrial conditions may be present.
• Employees must follow all applicable safety procedures and use required personal protective equipment (PPE) when entering designated work areas.

Prepared by: Human Resources

Approved by: Senior Engineering Manager