Senior Product Development Engineer-Metal Forming/Processing

W3Global Inc.; Utica (MI); On-site; USD 90,000 - 130,000; Full time

Job summary

W3Global Inc. in Michigan seeks an experienced Senior Product Development Engineer to lead the development and launch of advanced cold forging and metal forming solutions for automotive, aerospace, and industrial markets.

This role blends hands-on shop-floor work with office-based design and project leadership to deliver robust manufacturing processes from concept through production. The candidate will work across engineering, tooling, production, and quality teams, applying Lean and Six Sigma

Qualifications

• Bachelor's degree in mechanical or manufacturing engineering or equivalent experience.
• 5-10 years of experience in product design and development, ideally in cold forging, stamping, extrusion, or metal forming.
• Experience with SolidWorks or similar 3D CAD software.
• Experience with metal forming simulation software is preferred.
• Strong project management and problem-solving skills; leadership capabilities.

Responsibilities

• Lead design and development of tooling using 3D CAD and cold forge simulation software.
• Collaborate with OEMs, Tier-1 suppliers, and internal teams to align design with manufacturing capability and cost targets.
• Manage prototype builds, trials, and assist with production launches, ensuring smooth transition to full-scale production.
• Drive process improvements through Lean and Six Sigma practices.
• Evaluate and implement new materials and forming technologies to enhance performance and efficiency.
• Support customer presentations, technical reviews, and product demonstrations.
• Oversee assigned engineering projects to meet cost, quality, and schedule objectives.
• Participate in product teams to provide technical guidance for continuous improvement.
• Leverage CNC metal processing knowledge to support prototype development, tooling design and cost optimization.

Skills

Project management

Problem solving

Team leadership

Lean Six Sigma

Manufacturing process development

Education

Bachelor's degree in mechanical or manufacturing engineering

Tools

SolidWorks

Job description

Job Description

Summary:

We are seeking an experienced Senior Product Development Engineer to lead the development and launch of advanced cold forging and metal forming solutions serving the automotive, aerospace, and industrial markets. This role is critical to driving new product and process development, supporting customer programs, and delivering robust, cost-effective manufacturing solutions from concept through production.

The ideal candidate is a hands-on engineer with a proven track record in metal forming, manufacturing process development, and new program launches. This individual will work closely with customers, tooling suppliers, production teams, and quality personnel to develop, validate, and optimize manufacturing processes. Success in this role requires a strong technical foundation combined with practical shop-floor experience, including process troubleshooting, tooling development, prototype builds, process validation, and continuous improvement initiatives.

The successful candidate will be comfortable working both in the engineering office and on the manufacturing floor, taking an active role in trial planning, press and tooling development, root cause analysis, production problem-solving, and launch support. Strong project management skills, a results-driven mindset, and the ability to transform product concepts into repeatable, high-volume manufacturing processes are essential to success in this role.

Key Responsibilities:

• Lead design, and development of tooling using 3D CAD and cold forge simulation software.
• Collaborate with OEMs, Tier-1 suppliers, and internal teams to align product design with manufacturing capability and cost targets.
• Manage prototype builds, trials, and assist with production launches, ensuring smooth transition from development to full-scale production.
• Drive process improvements through Lean and Six Sigma practices.
• Evaluate and implement new materials and forming technologies to enhance product performance and manufacturing efficiency.
• Support customer presentations, technical reviews, and product demonstrations.
• Oversee assigned engineering projects to meet cost, quality, and schedule objectives.
• Participate in product teams to provide technical guidance and insight for continuous improvement initiatives.
• Leverage CNC metal processing knowledge to support prototype development, tooling design and process cost optimization.
• All other duties as assigned.

Qualifications:

Education & Experience:

• Bachelor's degree in mechanical or manufacturing engineering or equivalent experience
• 5-10 years of experience in product design and development, ideally in cold forging, stamping, extrusion, or metal forming.
• Experience with SolidWorks or similar 3D CAD software required.
• Experience with metal forming simulation software is preferred.
• Strong project management and problem-solving skills. Technical & Leadership Skills
• Proven ability to lead cross-functional teams and deliver innovative solutions.
• Knowledge of Lean and Six Sigma methodologies.
• Excellent communication and interpersonal skills, including the ability to work with customers, suppliers, and internal stakeholders.
• Knowledge of CNC metal cutting/processing preferred.

Additional Requirements:

• Ability to pass pre-employment screening (background check, drug test, etc.).
• Commitment to company policies, procedures, and safety standards.