Senior Mechanical Engineer - Phone as a Key

Location: Northville, USA

About Us

FORVIA HELLA is a listed international automotive supplier operating under the umbrella brand FORVIA. The company specializes in high-performance lighting technology and automotive electronics. With the Lifecycle Solutions Business Group, FORVIA HELLA also covers a broad service and product portfolio for the spare parts and workshop business as well as for manufacturers of special vehicles. Currently, the company has around 36,500 employees at over 125 locations worldwide and generated adjusted sales of €8.1 billion in fiscal year 2024.

About the Role

FORVIA HELLA is seeking a Mechanical Engineer – Phone as a Key to join the growing body team. This role focuses on the mechanical development aspects of automotive programs in partnership with internal and external stakeholders. You will engage in product engineering for next-generation body control functions.

Responsibilities

• Guide the mechanical design and development of premium automotive key fobs, ensuring high-quality appearance, functionality, durability, and compliance with OEM requirements.
• Oversee Class A surface development and tolerance engineering, delivering superior gap & flush, visual quality, perceived value, and manufacturable designs.
• Design and develop plastic, die-cast, and sheet-metal components, applying Design for Manufacturing (DfM) principles to support high-volume, fully automated production.
• Integrate electronic components such as PCBs, antennas, sensors, and batteries into compact housings, ensuring mechanical robustness, functional reliability, and EMC/ESD compliance.
• Oversee the development of HMI systems and environmental protection solutions, including tact switches, button mechanisms, sealing concepts, and waterproof designs that meet durability and IP requirements.
• Coordinate cross-functional development activities with customers, suppliers, and global engineering teams, driving FMEA, industrialization, ramp-up, and successful series production.

Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Automotive Engineering, Mechatronics, or a related technical field.
• Minimum of 5+ years of experience in automotive mechanical product development, preferably involving key fobs, compact mechatronic devices, or premium interior components.
• Strong expertise in Class A surface design and premium visible components, with proven experience delivering high-quality appearance, aesthetics, haptics, and perceived customer value.
• Experience integrating electronics into mechanical designs, including PCB packaging, EMC/ESD considerations, and development of reliable mechatronic products.
• Advanced knowledge of manufacturing and product development processes, including injection molding, DfM, GD&T and Tolerance Stacks analysis, FMEA, FEM, and high-volume automated production.
• Excellent hands-on experience in CAD tools (CATIA, Siemens NX, or Creo) and automotive development standards, combined with experience working with international OEMs and fluent English communication skills.
• Experience with SAP PLM or similar systems.

Benefits

• Hybrid work schedules and flexible core hours.
• Industry-leading health benefits program.
• Lucrative PTO policy.
• Competitive 401K matching.
• Extensive career and training opportunities.
• Annual bonuses.
• On-campus restaurant as well as employee water and coffee services.
• Team and company-wide events.