Job Description

Aegis Worldwide

Sr. Design Engineer

Direct Hire

Logansport, IN

Job Summary

The Senior Design Engineer is responsible for leading the design, development, validation, and launch of automotive components and systems for manufacturing and assembly. This role requires deep technical expertise in vehicle engineering, structural and sheet metal design, materials selection, and manufacturing processes, along with strong experience in APQP-driven product development. The ideal candidate will ensure designs meet performance, quality, cost, and timing requirements while supporting reliable, manufacturable, and serviceable vehicle solutions.

Key Responsibilities

• Lead and execute component and system design activities across the full product development lifecycle using APQP methodology, from concept through production launch.
• Apply a strong understanding of vehicle engineering and system integration, ensuring designs meet functional, durability, safety, regulatory, and reliability requirements.
• Design and validate automotive structures and assemblies with emphasis on structural integrity, manufacturability, and assembly efficiency.
• Develop and review sheet metal designs, including fabrication methods, welding processes, joining techniques, and assembly strategies.
• Apply LEAN manufacturing principles to optimize design for cost, efficiency, and waste reduction.
• Design and support vehicle systems including fuel, exhaust, cooling, and braking systems, ensuring compliance with applicable materials specifications, performance requirements, and automotive industry standards.
• Support and contribute to the design of vehicle compartments and systems such as Closures (doors, hoods, liftgates) and Suspension components, ensuring proper packaging, durability, and performance.
• Evaluate and select materials (steel, aluminum, composites, plastics, etc.), demonstrating a strong understanding of material properties, trade-offs, and benefits based on performance, cost, weight, and manufacturability.
• Perform and interpret CAE and validation activities, including FEA and physical testing correlation.
• Apply quality and design tools such as:
• DFMEA / PFMEA
• DVP&R
• DFA / DFM
• DOE
• GD&T and tolerance stack-up analysis
• Lead and participate in structured problem-solving activities using methodologies such as 8D or equivalent.
• Collaborate cross-functionally with manufacturing, quality, suppliers, purchasing, and program management to support design releases, issue resolution, and production readiness.
• Support supplier development, technical reviews, and design validation activities as part of the APQP process.
• Mentor junior engineers and provide technical guidance and design best practices.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Automotive Engineering, or a related discipline (Master’s degree preferred).
• 7+ years of experience in automotive design engineering within a manufacturing and assembly environment.
• Strong hands-on experience with APQP and product development in an automotive OEM or Tier 1/Tier 2 supplier environment.
• Proven experience in structural design, sheet metal components, and welded assemblies.
• Solid understanding of automotive systems including fuel, exhaust, cooling, braking, closures, and suspension systems.
• Strong working knowledge of automotive materials and their application in vehicle design.
• Proficiency with CAD tools (e.g., CATIA, NX, SolidWorks) and engineering analysis tools.
• Demonstrated experience with FEA, GD&T, tolerance analysis, and validation planning.
• Familiarity with automotive standards and regulatory requirements.
• Strong communication skills and ability to work effectively in cross-functional teams.

Preferred Qualifications

• Experience supporting new product launches and production ramp-up.
• Knowledge of global automotive quality standards (IATF 16949, ISO).
• Experience working directly with suppliers and manufacturing plants.
• Background in cost optimization and value engineering.

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