Design & Release Engineer - Exterior Trim (Functional Plastics)
Confirmed on the employer's own hiring board on Oct 25, 2026. First seen by Alion on Oct 4, 2026. SEGULA Technologies scores A on the Alion truth index.
Position Overview
We are seeking a Mid-Level Design & Release Engineer (DRE) specializing in Exterior Trim (Functional Plastics) to lead the engineering development, integration, and release of functional exterior plastic components. In this hybrid role, you will be responsible for managing components throughout their lifecycle-from initial styling surfaces through tooling validation and plant production launch. You will focus on high-visibility, functional exterior plastic assemblies such as front/rear bumpers, fascias, grilles, wheel arch claddings, rocker panels, and structural plastic brackets, ensuring they meet aerodynamic, impact, thermal, and fit-and-finish standards while collaborating with OEM design studios, tooling suppliers, and manufacturing plants.
Key Responsibilities
Plastic Component DRE Management: Lead the design, packaging, engineering release, and change management (DCN/ECN) for functional exterior plastic components and structural plastic mounting interfaces.
Injection Molding & Tooling Integration: Evaluate plastic part design for injection molding feasibility, draft angles, wall thickness consistency, rib design, sink mark prevention, gate locations, and mold tooling action constraints.
Functional & Fastening Packaging: Design robust attachment strategies using clip towers, heat stakes, ultrasonic welds, snap-fits, brackets, and structural fasteners to ensure proper gap and flush alignment with body-in-white (BIW) and lighting systems.
3D CAD & Surface Clearance: Execute 3D CAD packaging studies, dynamic clearance evaluations, thermal expansion allowance checks, and A-surface quality preservation in Siemens NX or CATIA V5/3DEXPERIENCE.
Quality & Stack-up Control: Establish GD&T datum schemes, conduct 3D tolerance stack-up analyses, manage DFMEAs, and maintain accurate Bills of Materials (BOM) within PLM environments.
Validation & Testing Support: Interpret CAE analysis results (low-speed pendulum impact, pedestrian protection, airflow/aerodynamic drag, paint adhesion, environmental thermal cycling) and lead physical trial builds to resolve fitment or surface defect issues.