Mechanical Systems Engineer, Exterior Sensor Integration

Workplace: On-site, 5 days per week
Location: Long Beach, CA

You will be a key contributor within a world class automotive body exterior engineering team, responsible for the mechanical integration of ADAS and autonomy sensors into the vehicle exterior and for the cleaning systems that keep them functional. This role owns the physical envelope around cameras, radars, lidars, and ultrasonic sensors, including packaging, field of view protection, mounting stiffness and alignment, thermal and environmental robustness, and the washer and air based cleaning architecture that serves them. You will work at the boundary between exteriors, ADAS and perception, electrical, thermal, closures, and supplier partners to deliver sensor installations that perform in the real world and survive production variation.

Responsibilities:

• Lead mechanical integration of exterior mounted ADAS sensors including forward and surround cameras, radar, lidar, and ultrasonic sensors across fascias, grilles, windshield, roof, closures, mirrors, and liftgate locations
• Own field of view and line of sight analysis, including obstruction studies, aperture sizing, sensor pointing angle definition, and coordination with perception and ADAS teams on FOV and coverage requirements
• Define and release sensor brackets, housings, covers, and mounting interfaces, balancing stiffness, mass, cost, tolerance capability, and serviceability
• Drive sensor alignment and positional accuracy strategy, including tolerance stack up to the sensor optical or antenna reference, datum and locator schemes, and end of line calibration feasibility
• Own the exterior sensor cleaning architecture, including nozzle design and aiming, washer fluid routing, pump and valve selection, air assisted and telescopic nozzle concepts, heated nozzle and heated lens strategies, and fluid volume and reservoir sizing
• Define and validate cleaning performance requirements and test methods for soiling, mud, salt, insect, ice, and snow conditions, including spray pattern coverage, cleaning efficiency, dry out behavior, and cycle time
• Coordinate with thermal and electrical teams on sensor heat rejection, heater circuits, condensation and fogging mitigation, harness routing, connector sealing, and grounding
• Manage radar transparency and material compatibility requirements for emblems, fascias, and covers, including thickness control, paint and coating constraints, and attenuation targets
• Manage component level DFMEA, DVPR, boundary diagrams, and robustness checklists for sensor and cleaning subsystems through design and release milestones
• Support water management, sealing, and ingress protection for sensor apertures and cleaning hardware, including IP rating verification and high pressure wash and car wash durability
• Collaborate with suppliers on design feasibility, tooling, process capability, cost targets, and on time delivery of sensor mounting and cleaning components
• Support prototype builds, buck reviews, and vehicle level test events, resolving sensor blockage, misalignment, calibration, and cleaning performance findings
• Support homologation and regulatory needs relevant to sensor visibility, pedestrian protection interaction, and applicable ADAS and NCAP requirements

Required Skills:

• Bachelor's degree in Mechanical, Automotive, or Systems Engineering, or equivalent experience
• 5+ years of automotive mechanical engineering experience, with direct work on ADAS or autonomy sensor integration at the vehicle level
• Hands on experience packaging and releasing exterior mounted sensors and the brackets, housings, or apertures that carry them
• Working knowledge of camera, radar, lidar, and ultrasonic sensor operating principles and the mechanical constraints each imposes
• Strong GD&T, tolerance stack up, and datum strategy skills applied to precision mounted components
• Experience with injection molded plastics, sheet metal, and die cast components, including DFM and tooling constraints
• Demonstrated ownership of DFMEA, DVP&R, and test plan development through validation and release
• Proficiency with CATIA V5, 3DEXPERIENCE, or Siemens NX, and PLM release systems such as Teamcenter
• Strong cross functional communication skills and the ability to negotiate requirements between exteriors, ADAS, electrical, and manufacturing
• Willingness to work onsite in Long Beach, CA

Bonus Skills:

• Direct experience with sensor cleaning or washer systems, including nozzle development, fluid delivery, e valves, or heated cleaning hardware
• Experience with ADAS sensor calibration processes, both end of line and service level, and their mechanical prerequisites
• Familiarity with radome design, radar attenuation testing, and material selection for RF transparency
• Experience with CFD, thermal analysis, or spray and soiling simulation applied to sensor cleaning or contamination
• Exposure to functional safety and SOTIF concepts as they relate to sensor availability and degradation
• Prior work on an electric vehicle or L2 plus autonomy program from concept through start of production
• Experience with environmental and durability test development including thermal cycling, humidity, vibration, salt spray, and stone impact

Salary Range:

• $130,000-$145,000
• 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

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.