Sheet Metal Designer

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more. As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing. When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow. Role Overview You will be a key contributor within a world-class automotive body structures engineering team, responsible for the development and delivery of sheet metal components and assemblies for. This role focuses on detail design, structural feasibility, and launch execution, working closely with body engineering, manufacturing, stamping suppliers, and cross-functional program teams to deliver production-ready sheet metal solutions from concept through SOP. Key Responsibilities Lead or support the engineering, packaging, release, and launch of body sheet metal components including closures, body-in-white structural members, reinforcements, brackets, and attachment systems across the UEV vehicle architecture Translate body design and structural intent into production-feasible, stampable sheet metal designs that meet functional, dimensional, and manufacturing requirements Define and own GD&T datum and locating strategy for sheet metal assemblies; perform tolerance stack-up and dimensional variation analysis to ensure fit, function, and assembly compliance Manage component-level DFMEA, DVPR, SCCAF, boundary diagrams, and robustness checklists through design and release milestones Work cross-functionally with body structures, closures, chassis, manufacturing engineering, purchasing, and program teams to prioritize overall vehicle performance and timing Collaborate closely with stamping and forming suppliers to ensure tooling feasibility, steel-safe progression, blank optimization, and on-time program delivery Perform and support DFM assessments, formability analysis, springback prediction, and weld/join feasibility reviews for sheet metal assemblies Define material specifications including grade, thickness, coating, and surface finish requirements; support material substitution trade studies for mass and cost optimization Support prototype builds, body buck reviews, and dimensional quality resolution through gauge studies and closed-loop corrective action Maintain PLM/BOM accuracy and manage engineering documentation through Ford's product development system Apply and continuously improve engineering tools, methods, and best practices to support accelerated development on a fast-paced EV startup-style program Required Qualifications 4+ years' experience in automotive sheet metal design and release engineering (body structures, closures, BIW reinforcements, brackets, etc.) Strong understanding of sheet metal manufacturing processes including stamping, progressive die, roll forming, hydroforming, and spot/laser welding Proficiency in CATIA V5/V6 or equivalent CAD tools; working knowledge of GD&T per ASME Y14.5 and tolerance analysis methods Experience supporting vehicle or product launches, including supplier tooling sign-off, first article inspection, and manufacturing readiness reviews Familiarity with DFMEA, DVPR, and structured quality documentation processes Nice to Have / Advantageous Ownership of at least one full program lifecycle from concept through SOP in a body structures or closures role Experience in a fast-paced OEM or EV startup environment with compressed development timelines Deep knowledge of high-strength and advanced high-strength steel (AHSS/UHSS) selection, formability limits, and joining strategies for EV body architecture Familiarity with multi-material body strategies including aluminum stampings, roll-formed sections, and structural adhesive bonding as complements to steel construction Experience with CAE-driven design iteration including FEA for stiffness, NVH, and crash load path interpretation Understanding of EV-specific body architecture considerations including battery enclosure integration, floor tunnel elimination, and high-voltage system clearance requirements Knowledge of corrosion protection systems, E-coat compatibility, and surface preparation requirements for sheet metal assemblies Competency in mass and cost optimization through gauge reduction, blank nesting, and part consolidation strategies Hands-on, practical engineering mindset with strong problem-solving skills in a prototype and pre-production environment Excellent communication skills with the ability to align across design, manufacturing, supply chain, and program stakeholders Salary Range: $120,000-$140,000/K The actual salary offered is dependent on various factors including, but not limited to, location, the candidate’s combination of job-related knowledge, qualifications, skills, education, training, and experience ALTEN Technology is an Equal Opportunity Employer. Our Policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of an individual’s age, race, color, sex, religion, national origin, disability, sexual orientation, gender identity/expression or veteran status. Please beware of job seeker scams and see this important notice on our careers page for more information about our recruiting process. Compliance Notice: Alten USA is a federal contractor subject to the requirements of the Vietnam Era Veterans’ Readjustment Assistance Act (VEVRAA) and Executive Order 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status. Drug Screening Requirement: As a federal contractor, Alten USA maintains a drug-free workplace. All candidates selected for employment will be required to successfully complete a pre-employment drug screening as a condition of hire.

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