Senior Product Development Engineer – Exterior Architecture Truck/SUV

We made history and now we work to transform the future—for our customers, our communities, and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

About the role

Ford Motor Company is dedicated to designing, manufacturing, and offering high-quality vehicles that meet the diverse needs of our customers. We are seeking a Body on Frame (BoF) Truck & SUV Structures Architecture Senior Engineer for our Dearborn, Michigan location. This role focuses on Body-in-White (BIW) Structures, particularly Pick-Up Box development, to create cost-efficient, lightweight vehicles that cater to various occupancy and propulsion systems while meeting accelerated program timelines.

You will develop robust design solutions for steel, aluminum, and mixed materials, including critical joining elements. Collaboration with Vehicle Hardware Engineering (VHE) Flexible Vehicle Architecture teams, Advanced Manufacturing, and Program Strategy & Planning organizations is vital to ensure compatible architecture designs with process assumptions.

Responsibilities

• Develop new BoF BIW architectures with a focus on Pick-Up Box development, aligning with advanced manufacturing and product cycle plan requirements.
• Collaborate with RIC, VO – Manufacturing, Materials Engineering, and Vehicle Program Teams to develop efficient and feasible BIW solutions supporting Quality and Cost efficiency objectives.
• Maintain knowledge of competitive benchmarks to understand Best-in-Class designs and develop advanced projects to surpass existing BoF Platform & Top Hat architectures.
• Work with Application engineering teams to optimize designs as a system, leveraging expertise in BoF BIW design.
• Support the development and institutionalization of best practices, design rules, and requirements in FEDE for BoF BIW design applications.
• Define and validate BoF architecture system assumptions for program applications during the development phase.
• Optimize standard and mixed-metal joint designs in BIW architectures.
• Cooperate with Architecture & Applications CAE-team for the development of new BoF architectures and optimization of existing platforms.
• Develop new lightweight designs, including Aluminum High Pressure Die Casting, Plastic-Metal Hybrids, Multi-Piece-Integration (MPI) technologies, and new material grades of aluminum and steel sheet materials.
• Deliver a robust hand-off to Applications Structures Engineering for seamless progression toward optimization without revolutionizing architecture designs.
• Use AI to improve development efficiency, reduce cost, and enhance quality.
• Ensure Ford remains a leader in BoF architectures while promoting enhancements and innovation to existing structure designs in production.
• Implement new architecture designs and joining processes into forward-model programs in line with GTDS principles, eliminating last-minute design pivots.
• Leverage Ford’s internal manufacturing assets to meet Exterior cost targets supporting EBIT.
• Use simulation tools to reduce dependency on external support and physical testing.
• Implement architecture strategies aligning with Ford Purchasing objectives for sourcing efficiencies.

Requirements

• Bachelor’s degree in Mechanical Engineering, Automotive Engineering, or a related engineering discipline (required).
• Minimum of 6 years’ experience in Body Structure product development, including direct advancement (UNV/UPV series), validation (FJD/DCV), and industrialization (launch).
• Experience with Advanced Technology development, particularly in body structure systems and mixed materials joining with aluminum.
• Perform feasibility analyses using CAD tools, including draft angle analysis, undercut detection, minimum bend radius validation for sheet metal, and clearance checks.
• Working knowledge of Engineering toolsets to derive, communicate, and publish 3D surfaces via Catia V5/TeamCenter Engineering and/or Catia V6/3DX.
• Experience with GPDS milestone delivery and knowledge of GTDS timing Milestones for new technologies.

Qualifications

• Master of Science degree in Engineering (preferred).
• Body Engineering Design and Release experience in Body Structures (strongly preferred).
• Strong skillset in Systems interaction and integration with frames, battery structures, Chassis, and Interior Trim.
• Strong written/verbal communication skills with demonstrated success in technical presentations.
• Demonstrated track record of strong Leadership Behaviors aligned with Leadership+.
• Strong collaboration and negotiation skills to drive global alignment.
• Strong team problem-solving skills, both technical and non-technical, to achieve collaborative outcomes.

Benefits

• Immediate medical, dental, vision, and prescription drug coverage.
• Flexible family care days, paid parental leave, new parent ramp-up programs, and subsidized back-up child care.
• Family building benefits including adoption and surrogacy expense reimbursement, and fertility treatments.
• Vehicle discount program for employees and family members, including management leases.
• Tuition assistance.
• Established and active employee resource groups.
• Paid time off for individual and team community service.
• Paid holidays, including the week between Christmas and New Year’s Day.
• Paid time off and the option to purchase additional vacation time.

Pay

This position is a salary grade 7-8 and ranges from $86,600 - $166,200. Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility, and competitive market value.

Schedule

This position is hybrid. Candidates who are in commuting distance to a Ford hub location may be required to be onsite four or more days per week.