Zadania
Job Summary
We are seeking a proactive and results-driven Design Release Engineer (DRE) – HVAC Airflow Loop to lead the end-to-end design, packaging, validation, and release of vehicle cabin air distribution systems. In this role, you will be responsible for the complete airflow path—from the fresh air intake, blower assembly, and HVAC air distribution housing (HVAC unit/case), down through ducting networks, mode doors/actuators, and cabin air registers.
You will ensure optimal cabin thermal comfort, defrost/demist performance, low acoustic noise (NVH), and high energy efficiency for both traditional Internal Combustion Engine (ICE) vehicles and Battery Electric Vehicles (BEVs), where HVAC efficiency directly impacts vehicle driving range.
Key Responsibilities
1. Airflow Loop Design & Packaging Integration
Lead the mechanical design, CAD packaging, and surface routing of cabin HVAC ductwork (defrost, face, floor, rear seat/console, and battery-assisted cabin loops), registers, and fresh/recirculation air intakes.
Work closely with Interior Trim, Instrument Panel (IP), Cockpit, and Structural Engineering teams to ensure tight packaging feasibility, ergonomic register placement, and robust mounting interfaces.
Optimize air distribution geometry to minimize pressure drop, air leakage, flow restriction, and wind noise/turbulence (NVH).
Apply Design for Manufacturability and Assembly (DFMA) to ensure easy assembly plant installation and serviceability.
2. Validation, Testing & Performance Optimization
Define and execute the Design Verification Plan and Report (DVP&R) for HVAC airflow components, including air volume distribution (CFM), defrost/demist time compliance, thermal comfort index, air-leakage rates, and acoustic testing.
Collaborate with Computational Fluid Dynamics (CFD) engineers to analyze internal flow paths, velocity profiles, and door kinematics; translate simulation results into CAD design improvements.
Support climate wind tunnel testing, cabin pull-down/soak testing, and physical prototype vehicle evaluations.
Drive root cause analysis (8D, 5 Whys, Ishikawa) for airflow imbalances, mechanical door binding, actuator noise, or cabin draft/noise issues.
3. Change Management & Release Execution
Author and manage technical releases, including Design FMEAs (DFMEA), 2D drawings, 3D CAD models, material specifications (e.g., blow-molded plastics, injection-molded polymers, foam seals), and GD&T scheme definitions.
Generate and process Change Notices (CNs/ECNs) to track technical revisions, tooling modifications, and cost-reduction initiatives across engineering and purchasing.
Issue Tool Kick-Off (TKO) approvals, manage Source Package technical releases, and issue Interim Approval Authorizations (IAAs) when necessary.
4. Supplier Management & Cross-Functional Interface
Act as the primary technical contact for Tier-1 HVAC unit, ducting, and register suppliers; oversee technical progression through APQP / PPAP milestones.
Interface directly with Thermal System Architects, Electrical/Software teams (for door stepper motor/actuator controls), Quality, Purchasing, and Assembly Operations.
Support Design-to-Cost (DtC) and weight-reduction initiatives without compromising acoustic or thermal comfort standards
Profil
Qualifications & Requirements
Education: Bachelor’s degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, or a related discipline.
Experience: 3+ years of experience as a DRE or Product Engineer specializing in automotive HVAC systems, plastic ductwork, or fluid/airflow distribution.
Technical Knowledge:
Deep understanding of automotive HVAC thermodynamics, fluid mechanics, psychrometrics, and acoustic principles.
Knowledge of automotive plastics and manufacturing processes (injection molding, blow molding, thermoforming, ultrasonic welding, foam sealing).
Working proficiency with 3D CAD software (CATIA V5/V6 or Siemens NX) for packaging, routing, and clearance checks.
Familiarity with CFD flow analysis interpretation and air distribution testing methods.
Process Familiarity: Solid working knowledge of DFMEA, DVP&R, GD&T, APQP, PPAP, and automotive release systems (e.g., Teamcenter, Enovia).
Languages: Business fluency in English (written and spoken).
Preferred Qualifications
Experience with BEV Heat Pump integration and eco-HVAC strategies (e.g., zonal air conditioning, intelligent air recirculation, micro-climate controls).
Experience with HVAC blend door, mode door, and recirculation door actuator integration and LIN bus diagnostics.
Key Competencies
Aesthetic & Functional Balance: Ability to balance technical airflow performance requirements with interior styling and ergonomics.
Cross-Functional Negotiation: Capable of negotiating tight packaging space under the Instrument Panel (IP) with surrounding structural and electrical commodities.
Methodical Problem Solver: Skilled in diagnosing complex airflow, sealing, and acoustic issues through data and physical testing.