The Director – Sheet Metal and Structural Engineering leads the design, analysis, validation, and industrialization of sheet metal and structural components for vehicle and equipment platforms. This role is accountable for delivering high-integrity structural solutions that meet performance, weight, cost, and manufacturability targets. The director collaborates closely with cross-functional teams in product design, manufacturing, CAE, materials, and supplier development to ensure timely execution and product excellence.
Lead end-to-end engineering of sheet metal and structural systems, including frames, body panels, brackets, enclosures, mounts, and load-bearing assemblies.
Oversee CAD modeling, drawing release, and DFMEA reviews for sheet metal components.
Guide structural design to meet crash, stiffness, fatigue, NVH, and regulatory requirements.
Work with CAE teams to iterate designs based on static, dynamic, thermal, and modal analysis.
Define material strategy (steel, aluminum, HSS, composite-metal hybrids) in alignment with product needs.
Ensure manufacturability through DFM/A principles and alignment with stamping, welding, and fabrication processes.
Collaborate with sourcing and supplier quality teams for component development, tooling readiness, and APQP milestones.
Support prototype builds, structural validation testing, and failure analysis for sheet metal assemblies.
Drive innovation in lightweight design, joining technologies, and cost reduction.
Mentor and develop a high-performing engineering team across multiple platforms or programs.
Structural Design Excellence:
Deliver robust, lightweight, and cost-effective structural solutions for chassis, body, and enclosure systems.
Ensure modularity and standardization across platforms.
Advanced Materials & Manufacturing Integration:
Select and validate appropriate sheet materials (CRCA, HSS, AHSS, aluminum, stainless, galvanized, etc.).
Collaborate with manufacturing to ensure feasibility in stamping, bending, and welding operations.
Simulation-Driven Engineering:
Integrate CAE (linear/nonlinear, fatigue, crash) early in the design phase to ensure performance-driven development.
Validate against load cases including torsion, bending, vibration, and environmental loads.
Cross-functional Collaboration:
Work with product design, BIW, chassis, electrical packaging, and integration teams to ensure seamless fitment and functional alignment.
Interface with testing and validation teams for proving ground feedback and updates.
Program & Team Leadership:
Manage project timelines, budgets, and milestones for sheet metal content.
Lead technical reviews, gate presentations, and change management across lifecycle stages.
Bachelor’s or Master’s degree in Mechanical, Structural, or Automotive Engineering.
15+ years of experience in structural and sheet metal engineering, with significant leadership experience.
Strong understanding of sheet metal design principles, structural integrity, crashworthiness, and GD&T.
Proficient in CAD (CATIA, NX, SolidWorks), PLM systems, and CAE interpretation.
Familiarity with joining methods (welding, riveting, adhesive bonding, clinching) and corrosion prevention.
Demonstrated success in developing and industrializing complex structural systems in automotive or equipment industries.
Excellent leadership, problem-solving, and cross-functional communication skills.