Air Intake Design Engineer

Stefanini North America and APAC; Auburn Hills (MI); Hybrid; USD 90,000 - 130,000; Full time

Job summary

Stefanini North America and APAC seeks an experienced engineer to design, validate air intake systems for ICE and hybrid vehicles. You will guide CAD/CAE, prototyping, testing, and supplier coordination to meet vehicle-level objectives.

Responsibilities include applying DFMEA/DVP&Rs, documenting activities, and supporting sourcing. Occasional onsite plant support and travel may be required as programs evolve.

Qualifications

• ABET-accredited BS in Mechanical or Electrical Engineering.
• 5+ years experience with air intake systems or related testing (NVH, Rise-Over Ambient, water fording).
• Experience with injection molding and blow-molding tooling.
• Experience leading suppliers and coordinating milestones.
• Knowledge of UG/NX CAD and powertrain controls.
• Willingness to travel domestically and internationally.

Responsibilities

• Coordinate CAD design, CAE, prototyping, and physical testing.
• Document design, analysis, prototyping, and testing activities.
• Support sourcing activities and manage supplier progress.
• Apply DFMEA and DVP&R methodologies to minimize risk.
• Provide onsite support at engine/vehicle plants as needed.
• Support post-launch quality concerns and process changes.
• Drive cost-reduction and value-optimization activities.

Skills

Air intake systems

CAD design

DFMEA

UG/NX CAD

Supplier management

Travel willingness

Education

BS in Mechanical or Electrical Eng (ABET)

Tools

Powertrain software

Job description

We are looking for candidate who will design, develop, and validate air intake systems for internal combustion engine and hybrid electrified vehicles. Components may include various types of low-pressure clean- and dirty-side ducts, air cleaners, make-up air hoses, resonators, air filters, brackets, and other related items. High-pressure charge ducts may also be included.

Responsibilities

Responsibilities include early packaging, design, and execution of components to meet air intake system, engine, and vehicle-level functional objectives.

Key Activities Include:

• Coordinating CAD design, CAE, prototyping, and physical testing.
• Documenting design, analysis, prototyping, and testing activities.
• Supporting sourcing activities, depending on program assignments.
• Coordinating and tracking supplier progress after sourcing to ensure part maturity and program milestones are achieved.
• Applying best-practice designs and methodologies, including Design Failure Mode and Effects Analysis (DFMEA) and Design Validation Plans and Reports (DVP&Rs), to minimize risk.
• Providing occasional onsite support at applicable engine and/or vehicle assembly plants.
• Supporting quality concerns after vehicle launch.
• Validating process changes.
• Supporting technical cost-reduction and value-optimization activities.

Experience Required

• Bachelor of Science degree in Mechanical Engineering, Electrical Engineering, or an equivalent field from an ABET-accredited program.
• Five or more years of experience with air intake systems or related engine- and vehicle-level testing, including NVH, Rise-Over Ambient, water fording, or similar testing.
• Experience with plastics manufacturing processes and tool design, particularly injection molding and blow-molding technologies.
• Experience leading and managing suppliers, including coordinating supplier deliverables and program milestones.
• Ability to manage multiple concurrent activities in a fast-paced engineering environment.
• Working knowledge of UG/NX CAD systems.
• Familiarity with powertrain software and controls.
• Knowledge of Client systems and processes.
• Green Belt certification or equivalent experience with proactive and/or reactive Design for Six Sigma (DFSS) quality tools.
• Willingness to travel domestically and internationally, generally between the United States, Canada, and Mexico, to supplier locations, corporate vehicle or engine assembly plants, proving grounds, and/or technical centers.

Skills Required

• Working knowledge of air intake systems and components.
• Ability to proactively communicate with teammates, stakeholders, and supervisors.
• Ability to work effectively and independently in a remote or hybrid workplace.
• General knowledge of CAD design.
• General knowledge of spreadsheets and presentation development.
• Ability to create and apply component- and system-level DFMEAs and DVP&Rs.