Product Development Engineer - Heat Exchanger Core Engineer

Ford, Inc; Dearborn (MI); Hybrid; USD 74,000 - 166,000; Full time

Benefits offered by this job

Medical, dental, vision coverage

Parental leave

Vehicle discount program for employees

Tuition assistance

Flexible work options

Job summary

Ford Motor Company is seeking a Design Engineer to lead heat exchanger design and development (condenser, radiator, CAC, battery cooling). You'll apply aluminum alloy materials knowledge, brazing, and laboratory analysis to deliver robust, cost-effective HEX components for vehicle systems.

Join cross-functional teams across PM, NVH, CAE and suppliers. You’ll own DFMEA, support sourcing decisions, and lead root-cause analyses to improve quality while collaborating in a hybrid work model.

Qualifications

• Bachelor of Science in Mechanical or Industrial Engineering or a related field.
• Strong DFMEA knowledge and implementation per AIAG/VDA.
• Laboratory experience in metallurgy related to heat exchangers.
• Knowledge in corrosion lab testing and material designs.
• Knowledge of materials and heat exchanger manufacturing processes (fluxing, brazing, EOL checks).
• Understanding investigation tools – SEM, FTIR, Surface Analysis Tools, TGA.

Responsibilities

• Support creation and maintenance of Core Engineering Documents (DFMEA/SCCAF Documents, Requirements and Test Procedures, etc.).
• Support application teams in sourcing decisions, validation planning, engineering sign offs and manufacturing site reviews.
• Signoff of DV/PV/SREA/DPA for HEX Components.
• Technical Problem Solving for Launch, Recall, Quality / Field Issues.
• Understand manufacturing process for all types of heat exchangers: tube/fin forming, stampings, injection molding, brazing and EOL leak check.
• Understand corrosion methodology for various types of heat exchangers (rolled tube, extruded tube, plate stack, etc). Able to conduct root cause analysis and work with suppliers on countermeasures and preventative actions.
• Understanding of Materials, Analysis Tools, Design and Manufacturing for HEX Components.
• Able to lead technical discussions to deliver optimized Refrigerant or Power Train Designs for use in vehicle systems.
• Must be able to work with other FORD organizations, labs, and outside suppliers to help direct solutions for issues.
• Support global applications teams with refrigerant and coolant based heat exchangers issue.
• Optimize designs for Cost reduction while maintaining quality performance.
• Interact with Refrigerant, Power Train, NVH, Controls and CAE teams.
• Collaborate with subsystem Technical Specialist within the company and with external suppliers.
• Support new technology/supplier development.
• Support strategy papers such as Modularity, Commodity Business Plan.
• Provide technical support for cost reduction ideas and quality improvements.

Skills

HEX design

DFMEA

Metallurgy lab

Corrosion testing

Materials knowledge

Heat exchanger manufacturing

Investigation tools (SEM/FTIR/TGA)

Technical leadership

Education

B.S. in Mechanical or Industrial Engineering

Master of Engineering (preferred)

Job description

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

In this position…

This position will lead all the heat exchangers (Condenser, Radiator, CAC, WCC, Battery Chiller etc.) with expertise on design, materials (Aluminum alloy) and manufacturing processes (brazing), and laboratory analysis techniques.

What you’ll do…

• Support creation and maintenance of the Core Engineering Documents (DFMEA/SCCAF Documents, Requirements and Test Procedures, etc.)
• Support application teams in sourcing decisions, validation planning, engineering sign offs and manufacturing site reviews.
• Signoff of DV/PV/SREA/DPA for HEX Components.
• Technical Problem Solving for Launch, Recall,Quality / Field Issues..
• Understanding manufacturing process for all types of heat exchangers: tube/fin forming, stampings, injection molding, brazing and EOL leak check.
• Understand corrosion methodology for various types of heat exchangers (rolled tube, extruded tube, plate stack, etc). Able to conduct root cause analysis and work with suppliers on countermeasures and preventative actions.
• Understanding of Materials, Analysis Tools, Design and Manufacturing for HEX Components.
• Able to lead technical discussions to deliver optimized Refrigerant or Power Train Designs for use in vehicle systems.
• Must be able to work with other FORD organizations, labs, and outside suppliers to help direct solutions for issues.
• Support global applications teams with refrigerant and coolant based heat exchangers issue.
• Optimize designs for Cost reduction while maintaining quality performance.
• Interact with Refrigerant, Power Train, NVH, Controls and CAE teams.
• Collaborate with subsystem Technical Specialist within the company and with external suppliers.
• Support new technology/supplier development.
• Support strategy papers such as Modularity, Commodity Business Plan.
• Provide technical support for cost reduction ideas and quality improvements.

You’ll have…

Minimum Requirements:

• Bachelor of Science in Mechanical or Industrial Engineering or a related field
• 3+ years of experience in HEX designs and development.
• The D&R Engineer is responsible for managing product release CAD and BOM structures, including assembly positioning and mass attribute analysis. This role also includes facilitating supplier data integration and developing CAD studies to support and drive design improvements.
• Strong DFMEA knowledge and implementation per AIAG/VDA.
• Laboratory experience in metallurgy related to heat exchangers.
• Knowledge in corrosion lab testing and material designs.
• Knowledge of materials and heat exchanger manufacturing processes (fluxing, brazing, EOL checks)
• Understanding of investigation tools – SEM, FTIR, Surface Analysis Tools, TGA.
• Key:
  • Ability to lead and align collections of people that do not directly report to this position.
  • Ability to institutionalize the key factors of thermal systems success and lessons learned through documentation (design rules, requirements, technical design guides, etc.) and to teach associated learning sessions.
  • Ability to form an opinion, communicate it effectively at all levels, and drive the company in a winning direction.

Even better, if you have …

Preferred

• Master of Engineering (electrical, mechanical, physics, systems, etc.) preferred.

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision, and prescription drug coverage
• Paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• Generous vacation time, sick/personal time, and paid holidays, including between Christmas Eve and New Year’s Day

This position is a salary grade 6 - 8 and ranges from $74,300-$166,200.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid with a requirement to be onsite four or more days per week.