Senior Design Engineer

Astemo Americas Inc. is seeking an experienced Senior Engineer – Materials & Structural to join the Suspension Core Engineering Team. This role is focused on shock absorber components and technologies and is ideal for a senior‑level engineer with a strong foundation in mechanical design, materials engineering, structural durability, and manufacturing processes.

The Core Engineering team is the technical backbone and component authority for shock absorber components and technologies, translating vehicle‑level requirements into robust, manufacturable damper solutions by owning engineering fundamentals, design standards, and validation methodologies across global programs.
In this role, the Senior Engineer will lead and influence material selection, structural integrity, durability performance, and manufacturability of shock absorber components supporting both passive and semi‑active systems. This position plays a critical role in development of new technology, global standard creation, industrialization support, and production issue resolution, working closely with design, simulation, manufacturing, quality, suppliers, and OEM customers.

Key Responsibilities
Lead materials and structural engineering activities for shock absorber components and sub‑systems, including tubes, rods, valves, weldments, brackets, and other load‑bearing parts
Apply mechanical design principles to ensure robust structural performance, durability, and functional integrity of damper components
Define and execute material selection strategies, balancing performance, durability, cost, weight, manufacturability, and regulatory requirements
Guide structural, strength, and fatigue analysis using FEA tools, and correlate analysis results with physical testing
Develop and maintain materials, coating, and structural design standards for shock absorber components
Support corrosion, durability, and material validation testing, including interpretation of results and definition of acceptance criteria
Review and approve 3D models and engineering drawings with detailed GD&T, ensuring alignment with functional and manufacturing requirements
Provide technical leadership in Design for Manufacturing and Assembly (DFM/DFA), collaborating with manufacturing and suppliers to ensure production‑ready designs
Lead and support DFMEA, DVP&R, and design reviews, ensuring material and structural risks are identified and mitigated
Investigate material, structural, or durability failures, perform root cause analysis, and define corrective actions for development or production issues
Collaborate with Tier‑2 suppliers, global engineering teams, and OEM customers on material, structural, and durability topics
Mentor and provide technical guidance to early‑career engineers within Core Engineering
Stay current with emerging materials, manufacturing technologies, and structural durability methods relevant to suspension and damping systems

Required Qualifications
Technical Skills
Strong fundamentals in:
Mechanical design
Materials science and metallurgy
Structural strength and fatigue
Manufacturing processes (forming, welding, heat treatment, surface treatments)
Proficiency in 3D modeling and 2D drawing creation with GD&T (CATIA or SolidWorks preferred)
Proficiency in Microsoft 365 applications.
Experience with structural and fatigue analysis (FEA/FEM) and test correlation
Solid understanding of DFMEA, DVP&R, and automotive development processes
Knowledge of corrosion behavior, coatings, and durability testing methods is a plus
Knowledge of vehicle dynamics and ride & handling fundamentals, including an understanding of how damper characteristics influence ride comfort, handling, and vehicle performance, is a plus.

Professional Skills
Strong analytical and problem‑solving abilities
Ability to work independently while providing technical leadership
Effective written and verbal communication skills
Comfortable collaborating across design, CAE, manufacturing, quality, suppliers, and OEMs
Willingness to support global teams and occasional travel

Education: Bachelor’s degree in Materials Engineering, Mechanical Engineering, or equivalent. Master’s degree preferred

Experience: 6+ years of applicable experience in automotive or mechanical product development
Strong background in suspension, shock absorbers, or highly loaded mechanical components preferred

Working Conditions
Occasional meetings outside standard business hours to support global teams
Domestic and international travel may be required on a limited basis
Ability to sit or stand for extended periods and lift up to 25 lbs
Standard workweek with flexibility based on project needs
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