Senior Design Engineer

Position Summary

We are seeking a Senior Design Engineer with advanced expertise in SolidWorks surface modeling and large-format thermoformed part design to support the development of commercial bus and specialty vehicle bodies. This role is critical to delivering exterior and interior components that meet high standards for aesthetics, aerodynamics, durability, and cost-effective manufacturability.

The ideal candidate will serve as a technical leader in the design of plastic and composite vehicle body components, with particular strength in managing complex surface data, imported geometry, and tooling considerations unique to heavy-duty thermoforming. This position requires close collaboration with industrial design, manufacturing, and supply chain partners throughout the product lifecycle.

Key Responsibilities

Product & Surface Modeling

• Develop complex, production-ready surface and solid models for commercial vehicle body panels using SolidWorks.
• Translate conceptual and industrial design intent into manufacturable designs, incorporating proper draft, wall thickness, attachment features, and cosmetic requirements.
• Ensure seamless integration of body components with chassis structures, subframes, and adjacent vehicle systems.

Thermoformed Part Design

• Design large thermoformed components including wheel arches, body cladding, fascia, and interior panels.
• Collaborate with tooling suppliers and internal fabrication teams to ensure mold accuracy, effective vacuum paths, thermal control, and optimized cycle times.
• Apply mold-flow principles and account for post-forming tolerances, trimming, and assembly variation in final designs.

Surface Repair & Data Optimization

• Evaluate, repair, and optimize imported CAD data (STEP, IGES) from third-party design sources.
• Reconstruct or replace incomplete, low-quality, or non-manufacturable surface geometry to meet cosmetic and dimensional requirements.
• Maintain high levels of surface continuity, curvature control, and Class-A finish quality where required.

Cross-Functional Collaboration & Production Support

• Partner with industrial design, manufacturing, quality, and supply chain teams to deliver integrated vehicle body solutions.
• Provide hands-on engineering support during prototyping, forming trials, validation builds, and production launches.
• Create, review, and approve production-ready drawings, BOMs, GD&T, and supporting technical documentation.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Industrial Design Engineering, or a related discipline.
• Minimum of 5 years of design experience in commercial vehicle, specialty vehicle, or automotive body manufacturing.
• Advanced proficiency in SolidWorks, with a strong focus on surface modeling.
• Demonstrated experience designing thermoformed components for heavy-duty transportation applications.
• Proven ability to repair and optimize complex imported surface data.
• Working knowledge of vehicle body assembly methods, fasteners, adhesives, and surface coatings.
• Familiarity with FMVSS and ADA requirements preferred.

Preferred Qualifications

• Direct experience with bus, truck, or van body systems.
• Strong understanding of thermoformable materials such as ABS, TPO, and similar plastics.
• Experience integrating structural reinforcements, including bonded inserts and subframe interfaces.
• Exposure to ERP-linked BOM management and PLM systems.