Design & Development Engineer - Body Structures, Body-in-White

Overview

This is a Design & Development Engineer role in automotive body-in-white (BIW), working on body structure parts for global OEM programs. You will design and develop brackets, reinforcements, side sills, pillars and door structures in sheet metal, extrusion or similar processes, including modifying existing body structures for new vehicle variants. The work covers 3D CAD and 2D drawings, packaging, DMU and virtual build checks, including welding, joining and assembly feasibility, and applying CAE results for crash, strength and durability as design changes. You will also select materials, gauges and joining methods to OEM standards, update DFMEA and DVP&R documents, release changes through PLM, and support suppliers through technical discussions, tooling reviews and sample quality loops. The ideal candidate has strong CAD skills in CATIA, 3DEXPERIENCE or NX, including sheet metal design, along with knowledge of joining methods, GD&T, stamping or extrusion design, and crash and body strength requirements.

Responsibilities

Design and development

• Design and develop BIW parts such as brackets, reinforcements, side sills, pillars and door structures in sheet metal, extrusion or similar processes.
• Create and modify 3D CAD models, assemblies and 2D drawings, including modifications to existing body structures for new vehicle variants or markets.
• Select materials, gauges and joining methods (spot weld, adhesive, fasteners) in line with OEM standards.
• Update surrounding body parts and mounting points affected by a change.

Packaging and validation support

• Carry out packaging studies, DMU checks and virtual build analysis, including welding, joining and assembly feasibility.
• Apply CAE results for crash, strength and durability requirements as design changes.
• Check the structure against safety and regulatory requirements, such as side impact and door strength.

Manufacturing and supplier coordination

• Design parts for stamping, extrusion and assembly, and apply supplier DFM feedback.
• Support supplier technical discussions, tooling reviews (including TKO and DFM loops) and sample quality loops.
• Follow open issues through to closure.

Documentation and release

• Prepare and update DFMEA, DVP&R and related design documents.
• Release engineering changes and data through the PLM system, following the OEM’s release process.
• Assess the impact of structural changes on neighbouring modules and raise change requests where needed.

Qualifications

• B.E./B.Tech (or equivalent) in Mechanical, Automobile, Automotive or a related field. An M.Tech is a plus.
• 6 to 9 years in automotive BIW or body structure design and development.
• Strong CAD skills in CATIA V5, 3DEXPERIENCE, NX or equivalent, including sheet metal design, assemblies and 2D drawings.
• Knowledge of spot welding, adhesive and fastener joining, GD&T, and stamping or extrusion design for manufacturing.
• Working knowledge of DMU, packaging and virtual build reviews.
• Understanding of crash and body strength requirements, with the ability to work from CAE inputs.
• Experience with DFMEA, DVP&R and the design release process.
• Familiarity with a PLM system such as Teamcenter or similar.
• Good communication skills for working with CAE teams, suppliers and cross-functional engineers.

Essential skills

Technical

• CAD design: Strong 3D modelling, sheet metal design, assemblies and 2D drawing skills in CATIA V5, 3DEXPERIENCE, 
• BIW design: Understanding of how brackets, reinforcements, side sills, pillars and door structures are designed, joined and assembled.
• Joining methods: Knowledge of spot welding, adhesive bonding and fastener joining, and how they affect part design.
• Manufacturing processes: Knowledge of stamping and extrusion design, material and gauge selection, and design for manufacturing (DFM).
• GD&T and tolerance analysis: Ability to define and review fits, locating schemes and tolerances for body parts.
• Packaging and DMU: Ability to run packaging studies and virtual build analysis, including weld access and assembly feasibility.
• Crash and strength awareness: Understanding of crash and body strength requirements, with the ability to apply CAE results as design changes.
• Design documentation: Working knowledge of DFMEA, DVP&R and design release procedures.
• PLM: Experience releasing data and engineering changes through Teamcenter or a similar system.

Working with others

• Supplier coordination: Experience with technical agreement, tooling reviews and sample quality loops.
• CAE collaboration: Ability to read simulation results and turn them into design changes.
• Communication: Clear reporting and discussion with cross-functional teams, clients and suppliers.
• Problem solving: Attention to detail and the ability to work to program deadlines.

Desired skills

• Experience modifying existing or carry-over body structures for new vehicle variants or markets.
• Knowledge of side impact, pole impact, door strength and other vehicle safety regulations (for example ADR, FMVSS or ECE).
• Experience with aluminium extrusion design or lightweight structures.
• Understanding of how BIW parts interface with interior, airbag and closure systems, such as pillar reinforcements and mounting brackets.
• Exposure to CAE and crash simulation workflows, enough to interpret results and drive design changes.
• Experience with advanced materials such as high-strength steel or aluminium alloys.
• Knowledge of welding, joining and assembly line constraints, including weld access and tool clearances.
• Experience working with global OEMs, international suppliers and cross-cultural teams.
• Familiarity with tooling and manufacturing feasibility reviews at supplier sites.

Experience

• 6 to 9 years in automotive design and development, with a background in OEM or Tier-1 BIW or body structure programs.
• Hands-on experience designing BIW parts such as brackets, reinforcements, side sills, pillars and door structures in sheet metal or extrusion.
• Experience taking parts through the full design cycle: concept or carry-over, CAD, packaging and DMU, weld and assembly feasibility, supplier DFM feedback, tooling and sample loops, and design release.
• Experience modifying existing body structures for new vehicle variants or markets, and updating the neighbouring parts affected by a change.
• Experience applying CAE results for crash, strength or durability as design changes.
• Experience preparing and updating DFMEA and DVP&R documents, and releasing engineering changes through a PLM system.
• Experience working with suppliers on technical agreement, tooling reviews and sample quality loops.
• Experience working with CAE and cross-functional teams, ideally with global OEMs, is preferred.

What do I need before I apply

Must-have

• CAD design: You can model parts and assemblies, work in sheet metal, and produce 2D drawings in CATIA V5, 3DEXPERIENCE, 
• BIW design: You understand how brackets, reinforcements, side sills, pillars and door structures are designed, joined and assembled.
• Joining methods: You know spot welding, adhesive bonding and fastener joining, and how they affect part design.
• Manufacturing processes: You know stamping or extrusion design, material and gauge selection, and design for manufacturing (DFM).
• GD&T and tolerance analysis: You can define and review fits, locating schemes and tolerances for body parts.
• Packaging and DMU: You can run packaging studies and virtual build analysis, including weld access and assembly feasibility.
• Crash and strength awareness: You understand crash and body strength requirements and can apply CAE results as design changes.
• Design documentation: You have worked with DFMEA, DVP&R and design release procedures.
• PLM: You have released data and engineering changes through Teamcenter or a similar system.
• Supplier and team collaboration: You can work with CAE teams and suppliers on technical agreement, tooling reviews and sample quality loops.

Good to have

• Experience modifying existing body structures for new vehicle variants or markets.
• Knowledge of side impact, pole impact and door strength regulations (for example ADR, FMVSS or ECE).
• Experience with aluminium extrusion, high-strength steel or lightweight structures.
• Exposure to crash simulation workflows, and to how BIW interfaces with interior, airbag and closure systems.
• Experience with global OEMs and international suppliers.

Benefits

• Health and wellbeing: Medical insurance for you and your family.
• Leave and work-life balance: Paid annual leave, public holidays and other perks.
• Global exposure: Work on programs for international automotive OEMs alongside cross-border teams.
• Learning and development: Access to training, certifications and upskilling.
• Career growth: Clear progression paths in engineering and program management, with internal mobility across Expleo’s business and domains.
• Inclusive workplace: An equal opportunity employer that values diverse backgrounds and experience.