HV Battery - Senior Mechanical Hardware Designer - Dearborn, MI

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Ford Product Development is about to deliver breakthrough products and services that will delight our customers and High Voltage Battery team is at the forefront of developing cutting-edge electric vehicle technology. We are seeking a passionate and experienced Mechanical Hardware Designer to join our innovative team and contribute to shaping the future of mobility. The Senior Mechanical Hardware Designer will play a critical role in the design and development of high-voltage battery components for our electric vehicle lineup. The ideal candidate will have a minimum of 5 years of automotive component design experience, with a focus on plastic components, busbars, wire harnesses, and plastic connectors. A strong background in mechanical engineering and proficiency in fastener selection is essential for success in this role.

Visa sponsorship is not available for this position. 

What you'll do...

Design and Development

• Design plastic components, busbars, wire harness, and plastic connectors.
• Create detailed 3D models and 2D drawings of those parts.
• Develop innovative designs that meet functional, manufacturability, and cost requirements.
• Perform design calculations, material selection, and tolerance analysis to ensure optimal performance and reliability.

• Select appropriate fasteners for various components, considering factors such as material compatibility, load requirements, and assembly processes.
• Integrate fastener choices seamlessly into the overall design.

• Work closely with cross-functional teams, including Electrical Engineering, Manufacturing, Quality Assurance, and Supply Chain, to ensure designs meet all stakeholder requirements.
• Participate in design reviews and provide expert insights to optimize designs.

• Ensure all designs comply with relevant industry standards, regulations, and company policies.
• Stay updated with the latest advancements in high-voltage battery technology and automotive design standards.

• Prepare and maintain detailed documentation of designs, calculations, and decisions made throughout the design process.
• Support the development of prototypes and oversee testing procedures to validate design integrity.

• Bachelor’s degree or higher in Mechanical Engineering or a related field
• Minimum of 5 years of experience in automotive component design.
• Proven experience in:
  • Plastic injection molding
  • Designing plastic housing and integrated features
  • Designing plastic connectors incorporated into plastic housing
  • Bus bar stamping and bending
  • Wire harness design
  • Ability to work with build to print suppliers for manufacturing above components
  • Proficiency in CAD to create 3D models and 2D prints for above component designs
• Familiarity with fastener selection and application in automotive assemblies.
• Proficiency in CAD modeling.
• Strong understanding of GD&T (Geometric Dimensioning and Tolerancing) and tolerance stack-up analysis.
• Knowledge of manufacturing processes such as injection molding, metal stamping, and extrusion.
• Experience with DFMEA (Design Failure Mode and Effects Analysis) and DVP&R (Design Verification Plan & Report).

• Master’s degree in mechanical engineering.
• Experience in high-voltage battery systems or electric vehicle components.
• Proficiency in CAD software (e.g., CATIA V5/V6).
• Familiarity with Ford’s engineering standards and product development processes.
• Knowledge of industry standards (e.g., ISO, SAE) related to automotive and electrical components.
• Experience with PLM (Product Lifecycle Management) systems.
• Excellent problem-solving abilities and attention to detail.
• Strong communication and interpersonal skills.
• Ability to work effectively in a team environment and manage multiple projects simultaneously.