BIW & Battery Housing Engineer

The BIW & Battery Housing Engineer will support advanced Body-in-White structural concepts, primarily large and medium structural castings, while also supporting stampings, extrusions, roll-formed sections, composites, and mixed-material assemblies. The engineer will provide expertise in casting feasibility, structural integration, joining strategy, corrosion protection, dimensional control, manufacturability, assembly, and supplier capability.

• Develop BIW concepts using structural castings, steel and aluminum stampings, extrusions, roll forms, composites, and hybrid assemblies.
• Lead casting reviews covering alloy, wall thickness, ribs, draft, parting lines, gating, porosity, distortion, machining, tooling, and datum strategy.
• Identify opportunities for part consolidation, joint reduction, attachment integration, mass reduction, and assembly simplification.
• Review structural sections, load paths, crash management, stiffness, fatigue, durability, and local attachment requirements with CAE teams.
• Develop mixed-material strategies using FDS, resistance/MIG/laser welding, FSW, SPR, bolts, mechanical fasteners, adhesives, and sealers.
• Evaluate joints for material stack, access, loading, fatigue, corrosion, sealing, heat input, distortion, cycle time, equipment, and repairability.
• Define flange, access, edge-distance, adhesive, surface-treatment, sealing, and corrosion requirements; support coupon and subsystem validation.
• Assess suppliers, simulations, tooling, process controls, machining, inspection, quality plans, prototype trials, and casting/joining root causes.

Requirements

• A Bachelor's degree in Mechanical, Materials, Metallurgical, Manufacturing, Welding Engineering, or a related field.
• +3 years of automotive BIW, structural, casting, materials, or joining experience.
• Demonstrated structural casting expertise, preferably aluminum HPDC, plus experience with two additional BIW processes.
• Strong knowledge of mixed-material joining, metallurgy, corrosion, fatigue, dimensional control, GD&T, DFMEA, DVP&R, PFMEA, and joint validation.
• Preferred: mega/giga castings, structural nodes, rails or battery housings; casting simulation, metallurgical testing, corrosion mitigation, NX/Teamcenter.