Electrical Systems Design Release Engineer
11 days ago
Carlsbad
Senior Design Release Engineer (DRE) — Electrical Systems \n Department: Electrical Systems \n Reports to: Director, Electrical Systems · Employment Type: Full-time/On-site \n \n Role Overview \n Senior Design Release Engineer (DRE) manages the design, release, and lifecycle of electrical/electro-mechanical modules and Off-The-Shelf (OTS) components. This role is ideal for an experienced engineer who thrives in a fast-paced start-up environment, where no job is too small, and where leadership means owning the details — from CAD and BOM accuracy to strategic design decisions and supplier execution. \n They will package circuit boards, integrate internal harnessing (LV/HV), drive enclosure tooling, manage change processes, support hands-on prototype builds, and deliver to program milestones. They are both a technical expert and a practical problem-solver who jumps in wherever needed to ensure successful execution. \n Key Responsibilities \n Product Ownership & Release \n\n • Serve as the technical lead and single point of accountability for assigned modules, from concept through SOP and sustaining.\n, • Manage detailed part-level execution while always considering system-level impact\n, • Own complete product definition including CAD, engineering requirements, drawings, GD&T, materials and sealing strategy\n, • Support prototype and pilot builds hands-on, resolving issues at the bench or on the line as needed.\n, • Prepare and release assembly documentation for box build assemblies (BBA)\n\n PCB & Module Packaging \n\n • Lead packaging of PCBs into enclosures, including connector layouts, stack-ups, thermal management, sealing, and EMC control.\n, • Own selection, qualification, and integration of off-the-shelf components (connectors, vents, fasteners, displays, grommets, thermal parts).\n, • Perform DMU/clash analysis and ensure manufacturability, serviceability, and robustness.\n\n Harnessing Inside Enclosures or Box Builds (LV & HV) \n\n • Design and integrate internal harnessing for both low-voltage and high-voltage systems within enclosures or BBAs\n, • Establish routing paths that meet electrical safety, mechanical constraints, bend radius, creepage/clearance, thermal considerations, and EMC requirements.\n, • Specify fixation methods (clips, cable channels, strain-relief points, clamps, grommet routing, tie-downs).\n, • Validate harness integration through:\n, • Fit checks and tolerance simulations\n, • Vibration/robustness assessments\n, • Thermal exposure and derating checks\n, • HV safety evaluations\n, • Environmental simulations\n\n Enclosure Design & Tooling \n\n • Own enclosure design for injection molding, die casting, sheet metal, machining, and rapid-prototype builds.\n, • Work with a vendor to define tooling strategy (class, gating, parting line, draft, T0/T1/Tn expectations).\n, • Drive DFM/DFA reviews, tooling kickoff, and sample evaluation with suppliers.\n, • Resolve tooling issues quickly, pragmatically, and collaboratively.\n\n CATIA / CAD / PLM \n\n • Create and manage high-quality CATIA V6/3DEXPERIENCE models and assemblies.\n, • Produce engineering drawings using GD&T (ASME Y14.5) and perform tolerance stack-ups.\n, • Maintain EBOM configuration in PLM systems with high accuracy and discipline.\n\n BOM Ownership \n\n • Own the Engineering BOM end-to-end:\n, • Part number creation and revision control\n, • Alternates and AML/AVL\n, • Effectivity management\n, • Completeness across subassemblies including consumables\n, • Ensure clean alignment between EBOM ↔ MBOM and support service BOM development.\n, • Fix BOM issues at a tactical level if needed — no job too small.\n\n Change Management (ECR/ECO) \n\n • Lead creation and implementation of ECR/ECOs, with clear problem statements, justification, impact analysis, and effectivity planning.\n, • Drive cross-functional approvals and ensure traceability to requirements, validation, and supplier inputs.\n, • Streamline ECO cycle time through proactive documentation and planning.\n\n Program & Timeline Management \n\n • Own schedules for assigned components, identifying dependencies, risks, and mitigation plans.\n, • Work with and manage contractors for short term projects\n, • Drive progress toward key milestones (Design Freeze, DV, PV, Tooling, PPAP, SOP).\n, • Work closely with suppliers on development, timing, and PPAP readiness.\n, • Step in hands-on to remove blockers in a start-up environment.\n\n Hands-On Prototype Build Support \n\n • Work directly with technicians and engineering teams on bench builds, mock-ups, prototype assemblies, and in-vehicle installations.\n, • Assemble PCB modules, install OTS components, test harness routing, fit internal harnesses, torque fasteners, and validate sealing.\n, • Run physical clearance checks, thermal interface installation, vent/gasket placements, and mechanical fastener operations.\n, • Document issues, root causes, and feed detailed learnings quickly back into design, BOM, and ECO processes.\n, • Support rapid iteration in a start-up environment where speed, flexibility, and hands-on problem-solving are essential.\n\n Minimum Qualifications \n\n • B.S. in Mechanical Engineering, Mechatronics, Electrical Engineering, or related field.\n, • 7+ years in DRE/Product Engineering in automotive or adjacent industries.\n, • Deep experience with CATIA and GD&T.\n, • Proven ownership of BOMs and ECOs in PLM systems.\n, • Expertise in PCB packaging, OTS integration, and enclosure design.\n, • Experience designing and routing LV/HV internal harnessing.\n, • Strong cross-functional leadership and the ability to execute hands-on when needed.\n\n Preferred Qualifications \n\n • Experience with ENOVIA/3DX\n, • Familiarity with APQP/PPAP, DV/PV testing, and automotive environmental standards.\n, • Strong understanding of reliability engineering.\n, • HV safety experience (creep/clearance, insulation, sealing).\n, • Supplier tooling oversight and rapid-iteration prototyping experience.\n, • Start-up experience strongly preferred.\n\n Tools & Systems \n\n • CATIA V5/V6/3DX\n, • PLM: 3DEXPERIENCE/ENOVIA\n, • MS Project / Smartsheet / Jira / Confluence\n, • Microsoft 365\n\n