Staff Mechanical Hardware Engineer - ECU

General Motors is transforming the automotive industry through vehicle electrification, central compute, and autonomous capabilities. The Staff Mechanical Hardware Engineer will lead the mechanical design, development, analysis, testing, and production review of enclosures and electrical controllers for next-generation software-defined vehicle electronics. The role collaborates with electrical engineers, suppliers, and cross-functional stakeholders to deliver manufacturable, thermally managed, and EMI-compliant products.

Responsibilities:

• Execute mechanical design of electronics packaging / housings / enclosures per program timing, leading to successful launch of the product
• Design mechanical components including castings, injection moldings, stampings, seals, vehicle interfaces, PCBA mounts, connector interfaces etc
• Perform design calculations, GD&T and tolerance stacks
• Create 3D-CAD math and lead CAD reviews with stakeholders
• Develop analysis and test plan for new designs, perform proof of concept tests and analysis
• Perform FEA (Structural, Vibration, Mechanical shock, Fatigue), Modal analysis
• Lead prototyping and testing, analyze test data, and make necessary adjustments to mechanical designs
• Lead DFx activities with suppliers and implement cost optimization strategies into design
• Work with electrical engineers and PCBA designers to integrate components into electro-mechanical systems
• Build partnerships with functional peers internally within GM and externally at suppliers to align on designs per development cycles
• Communicate design progress and risks to stakeholders and cross functional partners
• Create 2D-drawings for housing, sub-assemblies & PCB as per ASME standards

Requirements:

• BS in Mechanical Engineering or related discipline
• 10+ years of engineering experience in design and development of active & passively cooled electronics housings and enclosures
• Experience designing for EMI/shielding, Sealing (IP / water management), Thermal management (heat spreaders, TIMs, air and/or coolant flow)
• Exceptional collaboration and teamwork skills; demonstrated ability for working across functional and organizational boundaries
• Solid organizational skills and the ability to manage multiple projects simultaneously
• Proficiency in 3D CAD modeling (NX and Teamcenter), 2D drawings, tolerance analysis, design for manufacturability, and assembly
• Strong analytical skills and engineering fundamentals in solid mechanics, material science, heat transfer, mechanism design, and manufacturing
• Hands-on experience engaging with electronics manufacturers, hardware related suppliers, contract manufacturers and vehicle assembly / manufacturing teams
• Master's degree/PhD in Mechanical / Electrical Engineering
• Mechanical design of PCBAs, computers, or automotive electronics
• Strong understanding of thermal solutions and their application
• Knowledge of vibrational and structural analysis
• Experience with ASME Y14.5-2009 dimensioning & tolerancing standards