Exterior Lighting Engineer

Optimal; Dearborn (MI); Hybrid; USD 110,000 - 150,000; Full time

Benefits offered by this job

Hybrid work model

Job summary

Optimal in Dearborn, MI seeks an Exterior Lighting Engineer to own internal lighting design within Build-to-Print and AI-driven engineering. You’ll bridge mechanical, electrical, software and optical domains to deliver robust, manufacturable lighting solutions and advance digital tooling.

You’ll lead CAD/DFMEA sign-offs, participate in design reviews, develop ESOW/EC, and collaborate with suppliers and North American plants. Some travel; hybrid work four days in the office.

Qualifications

• Bachelor's degree in mechanical engineering or related field.
• 5+ years of experience in design, development, or launch of automotive lighting or similar components.
• CAD capable (CATIA, 3DX, Teamcenter) and familiarity with CAE tools.

Responsibilities

• Perform and review technical analyses of component and system studies (dimensional stacks, CAEs, dynamic simulations).
• Participate in Technical Design Reviews.
• Sign-off CAD in Teamcenter; prepare DFMEAs, SCCAF, boundary diagrams, P-Diagrams, and DVP&Rs.

Skills

Laboratory

Product Development

Electrical Engineering

3D Modeling

Optical Engineering

Injection Molding

Injection Mold Design

Design Release Engineer

Education

Bachelor's degree in mechanical engineering

Master's degree in Engineering

Tools

CATIA

3DX

Teamcenter

CAE tools

Job description

Position Description:

The Exterior Lighting Engineer is a multi-disciplinary technical authority responsible for the integrity, evolution, and in-house design ownership of lighting systems. As the department shifts toward Build-to-Print (BTP) models and AI-driven engineering, this role is the primary driver of OEM's internal technical foundation. This position bridges the gap between mechanical, electrical, software, and optical engineering. Whether focused on advanced development or application execution, the engineer is the primary lead in ensuring that lighting technologies are not only robust and manufacturable but also developed using the most advanced digital transformation tools available. Group being "core" works on all exterior lighting and all programs. We support the Applications team across all projects. (Headlamps, taillamps, chmsl, fog lamps, license plate lamps, etc.)

Responsibilities:

• Perform and/or review & sign off technical analyses of component/system functional and packaging studies such as: dimensional stackups (GD&T layouts), CAE's, dynamic calculations and simulations, etc.
• Actively participate in the Technical Design Reviews.
• Review and sign-off CAD in Teamcenter Develop Lighting System documents including DFMEAs, SCCAF, Boundary Diagrams, P-Diagrams, & DVP&Rs
• Lead design reviews based on Failure Mode Avoidance.
• Develop ESOW (Engineering Statement of Work), EC (Engineering concepts) and participate in the sourcing Process (SOBA, ED&T review, piece cost and tooling cost review. Identify validation, durability and functional tests required as per SDS & ES. (DVP / FEDE)
• Address issues with root cause analysis (8Ds, 3x5Why) and permanent corrective actions implementation.
• Apply knowledge of six sigma principles. Collaborate with STA with technical assistance through the Supplier Engagement Process.
• Travel to supplier manufacturing and testing sites when required.
• Travel to North America plants when required.
• Hardware & PCB Design: Develop schematics, layout recommendations, and component selections for LED driver boards, power regulation circuits, and EMC filtering.
• Embedded Software Development: Write and validate embedded C/C++ microcode for LIN/CAN network integration, diagnostic stacks, thermal foldback routines, and lighting animations.
• AUTOSAR & Cyber Security Compliance: Ensure software architecture complies with OEM AUTOSAR standards, functional safety (ISO 26262), and cybersecurity requirements.
• Thermal & Electrical Analysis: Perform thermal FEA modeling, circuit worst-case analysis (WCA), and electrical stress testing

Skills Required:

Laboratory, Product Development, Electrical Engineering, 3D Modeling, Optical Engineering, Injection Molding, Design/build injection molds., Design Release Engineer

• Laboratory - Hands on diagnosis and root causing of lighting issues on warranty lamps. Ability to use basic hand tools to dissemble lamps & inspect for issues, and test electronics. Use lab equipment such as microscope, multimeter, hand tools, light power tools.
• 3D Modeling - Utilize CAD software such as Catia V5 to develop lighting CAD (concept, fixtures, & small lamps for build to print)
• Optical Engineering - Design optical systems for small lamps
• Injection Molding - Design for manufacturing utilizing knowledge of injection molding. When developing 3D CAD, be capable of accounting for manufacturability
• Design/build injection molds - Design for manufacturing utilizing knowledge of injection molding. When developing 3D CAD, be capable of accounting for manufacturability
• Design Release Engineer - As we are trying to do build to print lighting in house, rather than tier 1 suppliers fully owned parts, this engineer would need to have capability to manage program / D&R type of work as well to deliver and validate parts on a program timeline, work with purchasing, part number generation, cost analysis, weight analysis, feasibility studies, collaborate cross functionally to fit our parts within other commodities.

Experience Required:

• Bachelor's degree or higher in mechanical engineering or a related field. 5+ years of experience in design, development, or launch of automotive lighting or similar components CAD Capable (such as CATIA, 3DX, Teamcenter) & familiarity with CAE tools and software.
• Benchmarking experience Integration and developing CAD studies to support and drive design improvements.
• Demonstrated ability to manage multiple issues effectively and efficiently Demonstrated ability to show initiative and prioritize workload.
• Ability to travel domestical and international.
• Proficient in MS Office apps such as Excel, Word, Power Point MS Teams, and MS Azure SharePoint.

Experience Preferred:

• Master's of Science in Engineering (Mechanical preferred).
• 7+ years of experience in design and release of Exterior Lighting Software literacy and mechatronics experience.
• Strong understanding of statistical analysis. 8D and 5Why corrective action and problem-solving skills.
• Experience with DFMEA's, PFMEA's, and SCCAF's Detailed understanding of materials, manufacturing technologies, and GD&T Ability to work in a fluid environment when overall vehicle targets, size, appearance, and manufacturing location are not always known.
• Ability to solve complex system issues and deal with a variety of concrete variables in situations where only limited standardization exists.
• Effective oral and written communication skills.
• Ability to adapt your role to a variety of applications and issues as required.

Additional Information:

• HYBRID (4 days per week in the office).
• As this is a hybrid position, the customer may request in-person interviews.
• Travel to supplier manufacturing and testing sites when required.
• Travel to North America plants when required.