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.
- Solid 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.

📌 Lead Engineer- Underrun Protection and Aero Covers (Passenger Car) (Pune)
🏢 BMW TechWorks
📍 Pune