Senior Design Engineer

Senior Design Engineer – Surface Modeling & Thermoformed Part Design

Shape the future of commercial vehicle design.

We’re seeking a Senior Design Engineer with deep expertise in SolidWorks surface modeling and thermoformed part design to lead the development of commercial bus and specialty vehicle body components. This role is pivotal in delivering bodies that are aesthetically refined, aerodynamically optimized, and cost-efficient to manufacture.

The right candidate will blend creativity with precision engineering—turning complex surfaces into manufacturable solutions that hold up in the toughest fleet and transit environments.

Key Responsibilities

Product & Surface Modeling

• Develop complex, production-ready surface models for exterior and interior vehicle panels.
• Translate conceptual surfaces into manufacturable designs with proper draft, wall thickness, and mounting features.
• Ensure seamless integration with chassis structures, subframes, and adjacent systems.

Thermoformed Part Design

• Design large-format thermoformed components (wheel arches, body cladding, interior panels).
• Collaborate with tooling vendors to ensure mold accuracy, vacuum paths, and cycle time efficiency.
• Incorporate mold flow principles and tolerance requirements into all designs.

Surface Repair & Data Optimization

• Evaluate, repair, and optimize imported surfaces (STEP, IGES) from external sources.
• Reconstruct low-quality data to meet stringent cosmetic and dimensional standards.
• Maintain surface continuity and curvature essential for automotive-grade finishes.

Cross-Functional Collaboration

• Work closely with industrial designers, supply chain, and fabrication teams.
• Provide engineering support during prototypes, form trials, and production launches.
• Deliver accurate drawings, BOMs, and GD&T documentation.

Required Qualifications

• Bachelor’s in Mechanical Engineering, Industrial Design Engineering, or related field.
• 5 years’ experience in vehicle body or specialty vehicle manufacturing.
• Advanced SolidWorks surface modeling expertise.
• Proven track record in thermoformed part design for transportation applications.
• Strong skills in repairing imported surfaces and managing complex CAD data.
• Knowledge of body assembly methods, fasteners, adhesives, and coatings.
• Familiarity with FMVSS and ADA regulations (a plus).

Preferred Qualifications

• Background in bus, truck, or van body engineering.
• Understanding of ABS, TPO, and thermoformable plastics.
• Experience with structural reinforcement integration (bonded inserts, subframes).
• Exposure to ERP/PLM-linked BOM management.

What We’re Looking For

• Detail-driven engineer with a passion for precision and cosmetic excellence.
• Clear communicator who thrives in cross-functional collaboration.
• Adaptive problem solver able to deliver under tight production timelines.
• Continuous improver who pushes product and tooling quality forward.