Design Engineer, Automotive lighting

Job Summary

The Design Engineer, Automotive Lighting, will be responsible for the design and development of lighting systems and optics specifically for electric two-wheeler projects. This role involves creating innovative lighting solutions such as headlamps, tail lamps, and indicators, ensuring they meet stringent aesthetic and functional requirements. The engineer will oversee testing, validation, manufacturability, and quality control, while collaborating with cross-functional teams to deliver high-quality lighting products aligned with vehicle architecture and regulatory standards.

Responsibilities

• Design and develop lighting and optical systems for various vehicle platforms including headlamps, tail lamps, and indicators.
• Conduct testing and validation of lighting systems and their interactions by understanding vehicle architecture.
• Develop prototypes that meet strict aesthetic and functional requirements.
• Ensure manufacturability of lighting components and implement quality control measures.
• Review tools, jigs, fixtures, and end-of-line test equipment at supplier locations.
• Manage electromechanical interaction, impact analysis, and tolerance stack-up.
• Coordinate and execute thermal, sealing, vibration, shock, and structural tests on 3D printed prototypes, off-tool samples, and design validation tests (DVT) of lights.
• Participate in and contribute to Design Failure Mode and Effects Analysis (DFMEA), Design for Manufacturing (DFM), Design for Assembly (DFA), Design for Cost (DFC), Design for Reliability (DFR), Design for Serviceability (DFS), and component selection/derating reviews.
• Conduct root cause analysis (RCA) on field failures and implement or recommend corrective and preventive actions (CAPA).
• Participate in regulatory testing such as Underwriters Laboratories (UL), Automotive Research Association of India (ARAI), Bureau of Indian Standards (BIS), and International Electrotechnical Commission (IEC) standards for electrical/electronic assemblies.
• Apply problem-solving techniques including 5-Why analysis, Fishbone diagrams, and RCA methodologies.
• Execute projects following Project Management Professional (PMP) and Agile methodologies.
• Collaborate with cross-functional teams to ensure successful execution of lighting projects with full ownership of assigned tasks.

Qualifications

• Bachelor’s degree in Engineering (Mechanical, Electrical, or related field) or equivalent.
• Experience designing complex automotive lamps with challenging aesthetic requirements.
• Proficient in material selection and manufacturing processes for plastics, sheet metal, and casting.
• Strong knowledge of automotive lighting regulatory standards.
• Advanced understanding of fasteners, inserts, surface treatment methods, and engineering plastics used in electronic packaging and vehicle peripherals.
• Knowledge of Geometric Dimensioning & Tolerancing (GD&T) and generation of First Article Reports (FAR).
• Familiarity with DFMEA, PFMEA, AFMEA, DFM, DFA, DFC, DFR, DFS, Poka-Yoke methods, sealing, and venting mechanisms.
• Experience working through at least one complete product development lifecycle.
• Understanding of Advanced Product Quality Planning (APQP), PFMEA, and basic tool design is advantageous.
• Exposure to Production Part Approval Process (PPAP) and supplier quality audits.
• Basic understanding of electronic components and their integration.
• Experience with Printed Circuit Board Assembly (PCBA) interaction and packaging considering power dissipation and Electromagnetic Interference/Electromagnetic Compatibility (EMI/EMC) requirements.
• Knowledge of thermal design, interface materials, and simulation is a plus.
• Proficiency in software tools such as CATIA, NX, SOLIDWORKS, Product Lifecycle Management (PLM) tools (Teamcenter, JIRA), FMEA tools, and Pugh Matrix.
• Basic understanding of Computer-Aided Engineering (CAE) tools such as Ansys, Speos, LucidShape.
• Familiarity with Arduino programming is an added advantage.
• Strong interpersonal, planning, and communication skills; a good team player.

Preferred Skills

• Experience with thermal simulation and interface materials.
• Knowledge of electronics packaging and EMI/EMC considerations.
• Exposure to Agile project management methodologies.
• Familiarity with supplier quality audits and PPAP processes.
• Basic programming skills in Arduino or similar platforms.

Experience

• Minimum experience in designing automotive lighting systems, preferably with electric two-wheeler projects.
• Experience in at least one full product development lifecycle.
• Hands-on experience with prototype development, testing, and validation.

Environment

• Work type: Full-time
• Work mode: Hybrid (combination of remote and in-office work)
• Location: Bangalore, India
• Typical work setting involves collaboration with cross-functional teams, supplier visits, and hands-on prototype testing.

Salary

• Estimated annual salary: ₹3,100,000 INR

Benefits

Not specified.