Sr. Mechanical Design Engineer - J0048808

Astemo Ltd.; Farmington Hills (MI); On-site; USD 90,000 - 150,000; Full time

Job summary

Astemo Ltd. in the United States is seeking an experienced mechanical engineer to design and optimize advanced ECU mechanical structures focused on software-defined mobility in the automotive industry.

The role involves 3D modeling in SolidWorks, tolerance analyses, and collaboration with hardware teams to ensure robust, production-ready designs suitable for high-volume manufacturing. Travel domestically and internationally is required.

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• Master's degree preferred.
• 5+ years in ADAS/ECU design or equivalent.

Responsibilities

• Design and develop mechanical structures for ECUs with thermal management.
• Perform 3D modeling and drafting using SolidWorks.
• Conduct tolerance stack-up analyses and apply GD&T.
• Collaborate with hardware teams to optimize ECU housing.
• Prepare BOM and detailed assembly drawings.
• Support production readiness for high-volume manufacturing.

Skills

ADAS/ECU design

Thermal management design

CAD/ SolidWorks

CAE analysis

D-FMEA/DRBFM

GD&T

Test planning

Communication

Independence / teamwork

Education

Bachelor's degree in Mechanical Engineering or related field

Master’s degree preferred

Tools

SolidWorks

MS Office

Job description

General Responsibilities

Under the direction of the Director, this role is responsible for the design, implementation, and optimization of advanced mechanical structures, with a strong focus on software-defined mobility solutions for the automotive industry.

Job Responsibilities

• Design and develop robust mechanical structures for ECU systems, ensuring accurate thermal management, and protection against environmental factors (e.g., vibration, shock, thermal cycling or sealing).
• Generate new concepts and validate them through experiments and engineering analysis.
• Collaborate closely with hardware engineering teams to optimize ECU housing designs, ensuring appropriate integration with electronic components, PCBs, connectors and wiring harnesses.
• Perform detailed 3D modeling and drafting using Solidworks CAD software.
• Conduct comprehensive tolerance stack-up analyses and apply GD&T principles to ensure manufacturing feasibility, functionality, and assembly accuracy.
• Develop and oversee mechanical testing protocols, including shock, vibration, and thermal cycling, to confirm system robustness and reliability.
• Evaluate and select appropriate materials and manufacturing processes (e.g., injection molding, die-casting, sheet metal stamping) to optimize quality, performance, manufacturability, and cost-efficiency.
• Collaborate with suppliers and internal production teams to ensure designs are production-ready and support smooth transition into high-volume manufacturing.
• Participate with Astemo US & Japan Design Engineering organizations in the original design / existing design improvements and performance validation of ECUs.
• Prepare comprehensive technical documentation, including Bill of Materials (BOM), detailed component and assembly drawings, and mechanical design specifications.
• Participate actively in cross-functional meetings, effectively communicating design progress, risks, and improvement recommendations.
• Follow the company’s quality policies and procedures.
• Uphold safety standards and environmental compliance.

Qualifications

Knowledge skills and abilities:

• At least 3 years of experience in ADAS (Advanced Driver Assistance Systems) or ECU design
• Design for thermal management with liquid cooling
• Experience with at least one mass production development project in ADAS or ECU.
• Strong understanding of automotive mechanical components and production quality requirements.
• Proficiency in CAD tools (e.g., SolidWorks).
• CAE skills including stress, thermal, and vibration analysis.
• Experience with D-FMEA DRBFM, Tolerance Stack, GD&T
• Ability to create test plans and execute development experiments.
• Strong communication and presentation skills.
• Ability to work both independently and as part of a team.
• Proficiency in Microsoft Office and general PC software applications.

Additionally, the ability to work independently with minimal direction is required as are strong verbal and written communication skills. Experience with PCs and application software, such as MS Office tools is also required.

Education

Bachelor's degree in Mechanical Engineering or related field (Master’s degree preferred).

Experience

Minimum 5 years of relevant experience with a Bachelor’s degree, or 2 years with a Master’s degree.

Job level determined by various factors such as organization size, responsibility, career stage, and capabilities.

Additional Requirements

• Ability to travel domestically and internationally as needed.
• Comfortable working in a professional office, testing environments, and occasionally in manufacturing settings.