Engineer - Suspension Structural Design

The Suspension BTP D&R Engineer is focused on internally designed components. This role directly designs, develops, and releases critical suspension structural components, such as stampings, castings, and forgings. The engineer owns the entire design and engineering loop, including creating 3D CAD models from scratch, conducting desktop CAE design optimization, and managing the official releasing and launch execution. This position provides end-to-end component ownership within Underbody Engineering, establishing robust in-house design capabilities for the suspension team.

• Proficiently uses CATIA V5/V6 and similar CAD software (e.g., 3DX, NX, SolidWorks), along with Teamcenter and Vismockup, to efficiently create and manage robust, parametric, and associative Build to Print (B2P) parts.
• Develop high-quality 3D CAD design concepts and alternatives promptly.
• Creates and manages assemblies, drawings, motion files, and other related CAD data, as well as the complete vehicle environment with all system interfaces.
• Author official 2D production drawings with advanced GD&T (Geometric Dimensioning and Tolerancing) to ensure assembly fitment and dimensional control.
• Utilize integrated desktop CAE tools to perform basic linear static structural analysis (stress, strain, deflection, mass optimization) for rapid design iteration and concept validation.
• Collaborate with Core CAE Specialist teams for advanced vehicle-level durability, fatigue, and crash safety sign offs.
• Apply engineering knowledge of structural components to interpret manufacturing guidelines (stampings, castings, forgings) and incorporate DFM/DFA rules directly into the CAD.
• Lead technical design reviews with manufacturing plants and tooling suppliers to ensure process compatibility and design feasibility before tool kickoff.
• Develop and maintain engineering foundation documents including Design FMEAs (DFMEA) and Special Control Characteristics (SCCAF).
• Review, analyze, and sign off on gauge and check fixture designs, supporting Significant/Critical Characteristics (SC/CC) capability studies during pre-production.
• Own the standard Ford D&R workflow within the Global Product Development System (GPDS), utilizing WERS, Teamcenter, and JIRA/AIMS for part release and issue tracking.
• Drive supplier execution through APQP phases, overseeing prototype development, Supplier PPAP approvals, and official sign offs.
• Lead root cause analysis and issue resolution using 8D and JIRA methodologies for dimensional, test validation, or manufacturing quality issues during launch.
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• Bachelor of Science in Mechanical, Mechatronics, Automotive, or Aerospace Engineering.
• Strong, proven experience in 3D modeling of structural components using CATIA (surface and solid design modeling).
• Practical experience in 2D drafting and mechanical drawing creation with robust application of GD&T.
• Basic knowledge of desktop FEA/CAE tools to evaluate load cases (stress, deflection) for design optimization.
• Clear understanding of structural manufacturing processes (metal stamping, casting solidification, forging flow) and DFM/DFA guidelines.
• Experience or familiarity with Ford product development systems (Teamcenter, WERS, GPDS, JIRA) is a strong asset.
• Strong analytical and problem-solving skills to manage complex technical issues under compressed program timelines.
• Excellent communication and teamwork skills in both Spanish and English to collaborate effectively with CAD/CAE specialists, purchasing, manufacturing plants, and external BTP suppliers.