Mechanical Engineer (Exp. with Plastics Components Design, Automotive Components Design, DFMEA)

We are seeking a highly skilled Mechanical Engineer with expertise in plastic component design for aftermarket automotive components and accessories. The candidate will be responsible for taking new product concepts from idea to production, including CAD design, material selection, test plan development, and laboratory validation. Strong knowledge of plastics/polymers, DFMEA, and product testing methodologies is essential.

Key Responsibilities

• Design and develop plastic components and assemblies for automotive aftermarket products and accessories using CAD tools (e.g., SolidWorks, CATIA, NX).
• Incorporate best practices for injection molding, such as appropriate wall thickness, uniform material distribution, draft angles, undercuts, ribs, bosses, and snap-fits to ensure moldability, structural integrity, and cost-effective manufacturing.
• Conduct feasibility studies, design calculations, and tolerance stack-ups to ensure manufacturability and performance.
• Select appropriate plastics/polymers and additives based on mechanical, thermal, and chemical requirements.
• Prepare and maintain DFMEA for new product designs to identify and mitigate potential risks.
• Develop and document test plans, validation protocols, and acceptance criteria for new designs.
• When required, design custom test setups or fixtures to validate unique design aspects, particularly for plastic mechanisms or assemblies involving tight tolerances or complex motion.
• Conduct lab testing of prototypes and production samples using standard test equipment (e.g., tensile testers, impact testers, hardness testers, thermal chambers).
• Analyze test results, prepare reports, and provide design recommendations for improvements.
• Collaborate with toolmakers and molding vendors during the design phase to address DFM (Design for Manufacturability) and DFA (Design for Assembly) requirements.
• Ensure compliance with industry standards, safety regulations, and customer requirements.
• Prepare and maintain complete engineering documentation such as design specifications, 3D models, 2D drawings, BOMs, test protocols, validation reports, and engineering change records, ensuring traceability and compliance with product development processes.

Work Experience

Qualifications

• Bachelor s degree (or higher) in Mechanical Engineering, Materials Engineering, or related field.
• 3 7 years of experience in plastic component design within automotive, consumer products, or related industries.
• Hands-on experience in CAD modeling and drawing creation (SolidWorks preferred).
• Strong understanding of plastics, polymers, injection molding, and other plastic forming processes.
• Experience with test plan creation, lab validation, and data analysis.
• Working knowledge of DFMEA and product risk management tools.
• Familiarity with industry standards (SAE, ASTM, ISO) related to plastics and automotive components.
• Strong problem-solving, documentation, and communication skills.
• Ability to work independently as well as in cross-functional teams.