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Novelis Senior Application Engineer, Design Technology in Novi, Michigan

Novelis is seeking an experienced automotive Body-in-White (BIW) / Closures Design Engineer for a key role in the new automotive Customer Solution Center (CSC), in Novi, Michigan. The CSC is responsible to develop Closure and BIW designs in collaboration with several automotive OEMs that balance cost, mass, and innovation that demonstrate the value of Novelis products. The Senior Design Engineer will develop designs on a broad scale while accounting for key details.

The successful candidate will be expected to create and guide 3D design and development of structures, weighing tradeoffs of different materials and joining methods as judged by cost, mass, and performance. This engineer will engage with the automotive commercial and technical teams to understand the OEM design approach and structural requirements and performance of Novelis material.

The Senior Engineer will collaborate with other ASCs around the globe. The CSCs will promote innovations in the area of aluminum applications to provide new technical solutions to customers and internal project teams. CSCs mission is to assure the adaption and validation of innovation and new products at customers. Many North American automotive OEMs are particularly interested in closures, and hence is a focus of this center. Closures may include side doors, liftgates, hoods, fenders, and EV battery enclosures. This role will report to the Senior Technical Manager of the CSC who will manage the priorities and strategic direction of the engineering team in Novi as described above.

This position will work closely together with the Novelis OEM customer alloy development teams, R&D Application Engineers, and colleagues in Novelis CSCs in Europe and Asia. Integration into a multinational team and adaption of the Novelis cultural beliefs and living the culture is key for the success of the individual and the team!


  • Build design concepts for Body-in-White and Closure automotive structures, evaluating tradeoffs either with OEMs directly, paired with other suppliers, or on internal Novelis projects meant to showcase new products

  • Effectively engage with Automotive OEM design engineers to collaborate on design projects that utilize Novelis products, trading off cost, mass, joining methods, formability, and structural performance.

  • Maintain cost models and performance records of designs developed through engagement with team members and OEMs to allow Novelis to understand the value of products and make strategic decisions

  • Develop project proposals and meet project deliverables, commitments and timelines

  • Complete detailed 3D CAD design work from concept to prototype-ready

  • Collect local technical needs on structural performance to share with R&D center and set up related projects to satisfy those needs

  • Help review development strategy such that Novelis development is congruent with market needs through discussions with product management teams, alloy development teams, OEM customer teams, and the R&D team


  • A successful candidate will have 5+ years of broad experience with high-volume designs of Body-in-White and/or Door-in-White assemblies with common structural materials, such as steel and aluminum alloys

  • Bachelor’s degree in Mechanical, Metallurgical or Materials Engineering. Master’s degree a plus

  • Part and assembly design expertise for all types of BIW structures (Al intensive, AHSS, mixed metal hybrid structures and doors) and the related CAD / CAE simulation knowledge

  • Ability to build and/or guide completion of body/closure designs from concept to prototype-ready in 3D CAD (e.g. CATIA, NX)

  • Experience understanding and incorporating findings of product (e.g. crash/ strength/ stiffness) and process (e.g. stamping) simulation models, with experience using the codes being a plus

  • Experience with detailed design feasibility of parts / modules made with different materials or grades

  • Understanding of real-world cost drivers and barriers to implementation of new technologies

  • Advanced practical understanding of the design guidelines for Al and steel BIW sheet metal parts is essential

  • Understanding of joining methods, sheet metal forming (aluminum a plus), corrosion mitigation strategies, and manufacturing processes is essential

  • Experience understanding topology and shape optimization results is desired

  • Knowledge of formability characterization and testing methods, such as FLC/FLD methods using DIC, LDR/LDH, Bulge and Shear testing along with practical formability testing

  • Strong interpersonal skills, both verbal and written, and capability to thrive in a multinational and multifunctional team environment

  • Aim to develop innovative solutions that balance structural needs and cost requirements

  • Ability to travel in the local or regional area up to 30% of the time

Novelis’ Novi office is located twenty-five miles northwest of the heart of the motor city. Its 50+ employees provide dedicated commercial technical and recycling teams for Novelis’ growing automotive customer base. Novi is also the location of the company’s newly announced Customer Solution Center which will accelerate innovation between Novelis and automakers for the next generation of vehicle design. As one of the fastest growing cities in Michigan Novi offers a host of destination shopping and specialty expos fine dining options and outdoor recreation activities. Our Novi team is a key sponsor to community events such as Habitat for Humanity and local schools with its FIRST Robotics team and STEM education programs.

iCIMS Requisition Number: 2020-34782

Name: Novelis Global R&T

Job Type: Standard

Street: 39550 W. Thirteen Mile Road