Lead Engineer- Underrun Protection and Aero Covers (Passenger Car)

Role

Lead Engineer- Underrun Protection and Aero Covers (Passenger Car)

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About the UNIT/ Unit Overview

Digital Product Engineering

Location

Pune

Experience:

8-12

Number of openings

1

What awaits you/ Job Profile

• You will shape the future BMW vehicle efficiency, underbody aerodynamics, thermal management, and vehicle protection systems by developing Underrun Protection and Aero Cover systems for passenger cars.
• You will contribute to concept development, CAD engineering, packaging, integration, validation, and industrialization of underbody protection and aerodynamic components.
• Develop and maintain 3D CAD models, assemblies, engineering drawings, and release documentation for underrun shields, underbody panels, aero covers, and associated mounting systems.
• Support vehicle package studies, aerodynamic optimization activities, prototype development, testing, and production implementation.
• Collaborate closely with Aerodynamics, Vehicle Integration, Body, Powertrain, Thermal Management, NVH, Manufacturing, Testing, Purchasing, and Supplier Engineering teams.
• Ensure compliance with aerodynamic efficiency, durability, crash, NVH, thermal, weight, cost, sustainability, and manufacturing requirements throughout the product development lifecycle.
• Support engineering change management and issue resolution activities from concept through series production.

What should you bring along

• Bachelor's or Master's degree in Mechanical Engineering, Automotive Engineering, Polymer Engineering, or a related field.
• Minimum 8-12 years of experience in automotive exterior, underbody, aerodynamic, or body systems development.
• Strong understanding of vehicle underbody systems and aerodynamic component integration.
• Experience working with OEMs or Tier-1 suppliers in body, exterior, aero, or underbody component development.
• Knowledge of automotive engineering release processes and product development methodologies.
• Experience in cross-functional vehicle development programs.
• Strong communication, problem-solving, and stakeholder management skills.
• Proficiency in English; German language skills would be an advantage.

Must have technical skill

• Design and development of:

• Underrun Protection Covers

• Front Underride Shields

• Underbody Protection Covers

• Battery Protection Shields

• Stone Impact Protection Systems

• Splash Protection Panels

• Strong understanding of vehicle ground clearance and protection requirements.

• Knowledge of load paths and attachment strategies for underbody components.

• Strong understanding of aerodynamic performance requirements.

• Experience supporting drag coefficient reduction initiatives.

• Knowledge of airflow management around:

Front Axle, Rear Axle, Battery Systems, Cooling Modules, Exhaust Systems, Rear Diffuser Areas

• Understanding of aerodynamic efficiency targets and vehicle range optimization for EVs.
• Knowledge of vehicle NVH requirements and underbody noise optimization techniques.
• Support component-level and vehicle-level validation activities.
• Conduct root cause investigations and corrective action implementation.
• Develop detailed CAD models, assemblies, engineering drawings, and release documentation.
• Perform tolerance stack-up studies and interface management.
• Create component specifications and engineering standards.
• Conduct design reviews and technical feasibility assessments.
• Manage engineering releases and design changes throughout the product lifecycle.
• Experience in Design for Manufacturing (DFM).
• Experience in Design for Assembly (DFA).
• Understanding of supplier tooling development and industrialization processes.
• Knowledge of cost optimization and value engineering methodologies.

Good to have Technical skills

• CATIA V5/V6 Part Design, Assembly Design, GSD, and Drafting.
• Teamcenter, ENOVIA, or equivalent PLM systems.
• GD&T and Tolerance Stack-up Analysis.
• CFD and Aerodynamic Development exposure.
• Wind Tunnel Testing knowledge.
• Vehicle Aerodynamics and Airflow Management.
• DFMEA, DVP methodologies.
• Lightweight Design and Material Optimization.
• Sustainability and Recyclability Assessment.
• Root Cause Analysis, 8D, Six Sigma, and Problem-Solving tools.
• Knowledge of underbody regulatory requirements.
• Supplier Management and Technical Coordination.
• Global vehicle development program experience.
• Cost Reduction and Value Engineering initiatives.

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