Position Overview

We are seeking a Mid-Level Design & Release Engineer (DRE) specializing in Exterior Trim (Functional Plastics) to lead the engineering development, integration, and release of functional exterior plastic components. In this hybrid role, you will be responsible for managing components throughout their lifecycle—from initial styling surfaces through tooling validation and plant production launch. You will focus on high-visibility, functional exterior plastic assemblies such as front/rear bumpers, fascias, grilles, wheel arch claddings, rocker panels, and structural plastic brackets, ensuring they meet aerodynamic, impact, thermal, and fit-and-finish standards while collaborating with OEM design studios, tooling suppliers, and manufacturing plants.

Key Responsibilities

• Plastic Component DRE Management: Lead the design, packaging, engineering release, and change management (DCN/ECN) for functional exterior plastic components and structural plastic mounting interfaces.

• Injection Molding & Tooling Integration: Evaluate plastic part design for injection molding feasibility, draft angles, wall thickness consistency, rib design, sink mark prevention, gate locations, and mold tooling action constraints.

• Functional & Fastening Packaging: Design robust attachment strategies using clip towers, heat stakes, ultrasonic welds, snap-fits, brackets, and structural fasteners to ensure proper gap and flush alignment with body-in-white (BIW) and lighting systems.

• 3D CAD & Surface Clearance: Execute 3D CAD packaging studies, dynamic clearance evaluations, thermal expansion allowance checks, and A-surface quality preservation in Siemens NX or CATIA V5/3DEXPERIENCE.

• Quality & Stack-up Control: Establish GD&T datum schemes, conduct 3D tolerance stack-up analyses, manage DFMEAs, and maintain accurate Bills of Materials (BOM) within PLM environments.

• Validation & Testing Support: Interpret CAE analysis results (low-speed pendulum impact, pedestrian protection, airflow/aerodynamic drag, paint adhesion, environmental thermal cycling) and lead physical trial builds to resolve fitment or surface defect issues.

Key Competencies

• Functional Plastics & Materials Expertise: In-depth knowledge of automotive thermoplastic materials (PP, ABS, PC/ABS, TPO), injection molding processes, mold flow analysis, and secondary finishing (painting, graining, chrome plating).

• Exterior Fastening & Attachment Design: Advanced skill in designing clip interfaces, locator schemes, thermal expansion slots, snap-fits, and structural plastic brackets.

• Engineering Change & Lifecycle Control: Proficient in routing Design Change Notices (DCN/ECN), maintaining revision control, and managing complex BOM structures.

• GD&T & Tolerance Stack-ups: Expertise in defining datum reference frames, locator strategies (2-1-1 principles), and tolerance stack-ups for flexible plastic parts against rigid BIW mating panels.

• Cross-Functional Collaboration: Strong communication skills to liaise across Styling Studios, Tooling Engineers, CAE teams, Manufacturing Operations, and Tier-1 plastic injection suppliers.

• Root Cause Analysis: Ability to systematically troubleshoot shop-floor fitment issues, sink marks, warpage, clip breakage, or paint adhesion failures using 8D or Ishikawa methodologies.

Required Qualifications & Experience

• Education: Bachelor’s Degree in Mechanical, Automotive, Polymer/Plastics, Mechatronics, or Manufacturing Engineering.

• Experience: 3+ to 5 years of experience as a Design & Release Engineer (DRE) or Product Engineer focused on automotive exterior plastic systems or functional trim.

• Software Proficiency: Advanced command of 3D CAD platforms (Siemens NX, CATIA V5, or 3DEXPERIENCE) and enterprise PLM systems (Teamcenter or Enovia).

• Manufacturing Knowledge: Deep understanding of plastic injection molding, tooling construction (core/cavity, lifters, slides), ultrasonic welding, and automotive exterior painting lines.

• Languages: Professional business proficiency in English and Spanish (written and verbal) for technical reporting and global engineering coordination.