Senior Design Lead - Sheet Metal, DFMA, Creo

HCL Technologies Limited; United States; On-site; USD 120,000 - 170,000; Full time

Job summary

HCL Technologies Limited in the United States seeks a Senior Design Lead for Sheet Metal DFMA with Creo proficiency to drive design strategy from concept through production.

You will mentor engineers, conduct design reviews, optimize manufacturability, and collaborate with cross-functional teams to deliver cost-effective, high-quality sheet metal and plastic components.

Qualifications

• Extensive experience designing components with stamping, molding, and machining.
• Disciplined team lead with ability to work independently.
• Strong GD&T knowledge and tolerance stack-up analysis.
• Proficient in Creo CAD for 3D modelling, sheet metal, and 2D drawings.
• Deep manufacturability understanding for sheet metal and plastic.
• Experience creating DFMEA and identifying product risks.
• Familiar with NPI/NPD processes, compliance requirements, and Windchill.
• Excellent stakeholder communication and proactive leadership.

Responsibilities

• Lead sheet metal design projects from concept to completion with quality and timelines.
• Apply DFMA principles to optimize manufacturing and reduce costs.
• Create detailed designs in Creo and collaborate across functions.
• Conduct design reviews, provide technical guidance, and mentor juniors.
• Partner with stakeholders to understand needs and present design proposals.
• Stay current with industry trends and best practices in sheet metal design.

Skills

Sheet metal design

DFMA

Creo/ProE

Leadership

GD&T

Windchill PDM/PLM

NPI/NPD

Tools

Creo CAD software

Job description

Career Opportunities: Senior Design Lead - Sheet Metal, DFMA, Creo (181832)

Requisition ID181832-Posted10/20/2026

The Senior Design Lead will oversee and lead the Plastic & Sheet Metal Design process, focusing on Design for Manufacturing & Assembly (DFMA), and proficiency in Creo/ProE. The primary responsibilities include driving the design strategy, ensuring efficiency in manufacturing processes, and utilizing Creo/ProE to deliver high-quality designs.

Requirements

Strong Experience in design of components with various manufacturing processes like, Stamping, Molding & Machining.

Disciplined team lead, ability to work independently and handle team

Experience in Geometric Dimension & Tolerancing (GD&T)

Experience in Tolerance stack up analysis.

Proficient in Creo CAD software (Creating 3D models, Sheet Metal, 2D drawing and Assembly)

Strong knowledge in manufacturability considerations for Sheetmetal & Plastic

Create DFMEA and identify relevant product risks.

Identifying the suitable material, apply DFM/DFA concepts in design and Familiar with latest engineering design and methods, tools, and processes.

Experience with standard NPI / NPD process. Understanding of compliance requirements.

Hands on experience in Windchill PDM / PLM for managing lifecycle of the components.

Ability to present and articulate ideas to key stakeholders and leadership team.

Excellent communication skills and Positive ‘can do’ and proactive attitude.

Quality mindset in design and documentation.

Key Responsibilities

• 1. Lead the sheet metal design projects from concept to completion, ensuring adherence to quality and timeline requirements.
• 2. Implement design for manufacturing & assembly (dfma) principles to optimize the manufacturing process and minimize production costs.
• 3. Utilize creo/proe software proficiently to create detailed designs and collaborate with cross functional teams.
• 4. Conduct design reviews, provide technical guidance, and mentor junior team members to enhance overall design capabilities.
• 5. Collaborate with stakeholders to understand design needs, generate innovative solutions, and present design proposals effectively.
• 6. Stay updated on industry trends, new technologies, and best practices in sheet metal design and manufacturing processes.

Skill Requirements

• 1. Proficient in sheet metal design principles and methodologies.
• 2. Expertise in design for manufacturing & assembly (dfma) to optimize production processes.
• 3. Advanced proficiency in creo/proe software for detailed design and modeling.
• 4. Strong problem-solving skills and the ability to work in a fast paced, dynamic environment.
• 5. Excellent communication skills to collaborate effectively with internal teams and stakeholders.
• 6. Attention to detail and a strong focus on delivering high-quality designs within project timelines.

Other Requirements

• 1.Any relevant certifications in Sheet Metal Design, Design for Manufacturing & Assembly (DFMA), or Creo/ProE are a plus.