Sheet Metal Designer

Were ALTEN Technology USA an engineering company helping clients bring groundbreaking ideas to lifefrom advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3000 experts across North America we partner with leading companies in aerospace medical devices robotics automotive commercial vehicles EVs rail and more.

As part of the global ALTEN Group57000 engineers in 30 countrieswe deliver across the entire product development cycle from consulting to full project outsourcing.

When you join ALTEN Technology USA youll collaborate on some of the worlds toughest engineering challenges supported by mentorship career growth opportunities and comprehensive benefits. We take pride in fostering a culture where employees feel valued supported and inspired to grow.

Role Overview

You will be a key contributor within a world-class automotive body structures engineering team responsible for the development and delivery of sheet metal components and assemblies for. This role focuses on detail design structural feasibility and launch execution working closely with body engineering manufacturing stamping suppliers and cross-functional program teams to deliver production-ready sheet metal solutions from concept through SOP.

Key Responsibilities

• Lead or support the engineering packaging release and launch of body sheet metal components including closures body-in-white structural members reinforcements brackets and attachment systems across the UEV vehicle architecture
• Translate body design and structural intent into production-feasible stampable sheet metal designs that meet functional dimensional and manufacturing requirements
• Define and own GD&T datum and locating strategy for sheet metal assemblies; perform tolerance stack-up and dimensional variation analysis to ensure fit function and assembly compliance
• Manage component-level DFMEA DVPR SCCAF boundary diagrams and robustness checklists through design and release milestones
• Work cross-functionally with body structures closures chassis manufacturing engineering purchasing and program teams to prioritize overall vehicle performance and timing
• Collaborate closely with stamping and forming suppliers to ensure tooling feasibility steel-safe progression blank optimization and on-time program delivery
• Perform and support DFM assessments formability analysis springback prediction and weld/join feasibility reviews for sheet metal assemblies
• Define material specifications including grade thickness coating and surface finish requirements; support material substitution trade studies for mass and cost optimization
• Support prototype builds body buck reviews and dimensional quality resolution through gauge studies and closed-loop corrective action
• Maintain PLM/BOM accuracy and manage engineering documentation through Fords product development system
• Apply and continuously improve engineering tools methods and best practices to support accelerated development on a fast-paced EV startup-style program

Required Qualifications

• 4 years experience in automotive sheet metal design and release engineering (body structures closures BIW reinforcements brackets etc.)
• Strong understanding of sheet metal manufacturing processes including stamping progressive die roll forming hydroforming and spot/laser welding
• Proficiency in CATIA V5/V6 or equivalent CAD tools; working knowledge of GD&T per ASME Y14.5 and tolerance analysis methods
• Experience supporting vehicle or product launches including supplier tooling sign-off first article inspection and manufacturing readiness reviews
• Familiarity with DFMEA DVPR and structured quality documentation processes

Nice to Have / Advantageous

• Ownership of at least one full program lifecycle from concept through SOP in a body structures or closures role
• Experience in a fast-paced OEM or EV startup environment with compressed development timelines
• Deep knowledge of high-strength and advanced high-strength steel (AHSS/UHSS) selection formability limits and joining strategies for EV body architecture
• Familiarity with multi-material body strategies including aluminum stampings roll-formed sections and structural adhesive bonding as complements to steel construction
• Experience with CAE-driven design iteration including FEA for stiffness NVH and crash load path interpretation
• Understanding of EV-specific body architecture considerations including battery enclosure integration floor tunnel elimination and high-voltage system clearance requirements
• Knowledge of corrosion protection systems E-coat compatibility and surface preparation requirements for sheet metal assemblies
• Competency in mass and cost optimization through gauge reduction blank nesting and part consolidation strategies
• Hands-on practical engineering mindset with strong problem-solving skills in a prototype and pre-production environment
• Excellent communication skills with the ability to align across design manufacturing supply chain and program stakeholders

Salary Range: $120000-$140000/K

The actual salary offered is dependent on various factors including but not limited to location the candidates combination of job-related knowledge qualifications skills education training and experience

All qualified applicants will receive consideration for employment and will not be discriminated against on the basis of race color religion sex sexual orientation gender identity national origin disability protected veteran status age genetic information or pregnancy.

Please beware of job seeker scams and see this important notice on our careers page for more information about our recruiting process.

Compliance Notice: Alten USA is a federal contractor subject to the requirements of the Vietnam Era Veterans Readjustment Assistance Act (VEVRAA) and Executive Order 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race color religion sex sexual orientation gender identity national origin disability or veteran status.

Drug Screening Requirement: As a federal contractor Alten USA maintains a drug-free workplace. All candidates selected for employment will be required to successfully complete a pre-employment drug screening as a condition of hire.