Design Release Engineer – Intake Air Handling System

Design Release Engineer – Intake Air Handling System

The Design Release Engineer (DRE) for the Intake Air Handling System is responsible for the design, development, and technical leadership in the creation, validation, and release of engine air intake ducts, intake manifolds, charge air coolers, and hot ducts. The role drives the design through all phases of the product lifecycle, including design concept, engineering validation, and production release through PPAP (Production Part Approval Process).

• Lead the design of the intake air handling system hardware that brings air into the engine.
• Develop and refine the air handling system for function, cost, and quality, durability, NVH, and other performance metrics.
• Support CAD modeling, FEA, and other design validation methods to ensure structural integrity and compliance with standards.
• Collaborate with other engineering teams (airflow, thermal, packaging) to integrate the air handling system into the different engines and vehicles.
• Manage design release activities from early concept through production, including the timely completion of B‑Sample, C‑Sample, X0, X1, X2, and X3 milestones.
• Own the Bill of Materials (BOM) and Engineering Change Notices (ECNs) for air handling systems.
• Ensure all parts meet quality, cost, and timing requirements.
• Drive the Production Part Approval Process (PPAP) for air handling components, ensuring compliance with all regulatory and customer specifications.
• Coordinate with cross‑functional teams, including manufacturing, suppliers, and quality, to ensure the successful release and implementation of designs.

• Provide technical leadership and support during the development and production stages to resolve design issues, material selection challenges, and process‑related problems.
• Lead DFMEA (Design Failure Mode and Effects Analysis) and other risk assessment activities to ensure design robustness and mitigate potential issues.
• Participate in the development of testing strategies for turbocharger components, including vibration, crash, and thermal testing.

• Work closely with suppliers to ensure design feasibility, cost competitiveness, and manufacturability of turbocharger components.
• Collaborate with validation teams to define and implement validation testing, ensuring turbocharger components meet functional and performance metrics.
• Partner with vehicle integration teams to ensure proper fitment, safety, and integration of turbocharger components into the overall vehicle platform.

• Develop and maintain engineering documentation, including design specifications, drawings, test plans, and validation reports.
• Ensure that all technical documentation is up‑to‑date and aligns with program timelines and PPAP requirements.
• Report on project status, timelines, and risk assessments to senior management and stakeholders.

• Bachelor of Science degree in Mechanical or Aeronautical Engineering or related degree field.
• A minimum of 5 years of relevant experience working with design and manufacturing of turbocharger components, including metal stamping and casting.
• Understanding of engine components related manufacturing processes, i.e. Aluminum/steel stamping, aluminum casting, machining, etc.
• Understanding of product development documentation such as DFMEA and DVP&R.
• Understanding of Mechanics of Materials, Sealing systems, CAE Analysis, and GD&T.
• Experience in selecting materials and manufacturing methods for mechanical components.
• Ability to author system/component level requirements.
• Strong interpersonal communication, team/leadership skills/experience.
• Strong oral and written communication skills.
• Strong project management skills/experience.
• Demonstrated understanding of structural analysis and failure modes of complex mechanical systems.

• Advanced degree in Mechanical or Aeronautical Engineering.
• Working experience in creation and execution of validation plans.
• Critical character traits to ensure success:
  Action Oriented, Dealing with Ambiguity, Customer Focus, Problem Solving.
• Working experience with 3D…