Engine Exhaust System Design Development Engineer Jobs

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Embarking on a new role within Marelli means taking on new challenges and seizing the opportunity to make a bigger, better, bolder impact!

We’re pioneers of the future of mobility. Our story is built on innovation and manufacturing excellence. Every day, we drive change and co-create what comes next. Our purpose is simple yet ambitious: "Let's push the boundaries together. We aspire to shape future mobility dreams and turn them into reality.”

Joining the Marelli Engineering team means becoming a part of something bigger, a place where you can explore your potential, pioneer innovation.

As a global yet fast-evolving company, we are always looking to grow and evolve our talents.

We are looking for a Development Engineer to join the Green Technologies Exhaust Systems Research & Development team, reporting directly to the R&D Manager.

This position is based at our office in Southfield, Michigan.

The successful candidate will support the development of exhaust systems and components from concept through production launch, ensuring compliance with customer requirements, durability targets, and manufacturing requirements.

• Lead the design and development of exhaust systems and components including Hot ends and cold ends of the exhaust system.
• Support product development activities from RFQ through SOP, including concept development, design validation, prototype builds, customer reviews, and launch support.
• Coordinate cross-functional activities with CAE, manufacturing, purchasing, quality, and suppliers to deliver competitive technical solutions.
• Ensure designs meet, durability, NVH, thermal protection, packaging, and cost requirements.
• Project Management: Lead and oversee engineering projects from conception to completion, ensuring timely delivery, budget adherence, and quality control.
• Customer Engagement: Act as the primary point of contact for customers throughout the project lifecycle. Gather and understand customer requirements and ensure they are incorporated into project plans.
• Technical Support: Provide technical expertise and support to both internal teams and customers. Translate customer needs into technical specifications.
• Design and Development: Collaborate with design and engineering teams to develop innovative solutions that meet customer needs and industry standards.
• Risk Management: Identify potential project risks and develop mitigation strategies to ensure successful project outcomes.
• Communication: Maintain clear, consistent, and proactive communication with all stakeholders, including customers, team members, and management.
• Quality Assurance: Implement and maintain quality management systems to ensure project deliverables meet or exceed customer expectations. Effectively apply required project management skills/tools to achieve successful project execution.
• Ability to follow design release procedures and prepare documents for Design Review milestones (e.g. DFMEA, Design concept sheet, risk assessment, design change history log).
• Work with engineering staff members at customer locations in the development of designs, specifications, and requirements.

• A Bachelor’s degree in Mechanical Engineering or equivalent required
• Proven experience in project management within an engineering environment.
• Strong customer service orientation with excellent interpersonal and communication skills.
• Familiar with 3D modelling systems such as NX, Catia etc.
• Knowledge of exhaust system design, emissions aftertreatment technologies, and vehicle integration requirements preferred.
• Understanding exhaust component manufacturing methods including tube forming, welding, hydroforming, stamping, and assembly processes.
• Knowledge of vehicle packaging, durability requirements, materials selection, vibration analysis, and thermal shielding strategies.
• Familiarity with emissions regulations and aftertreatment technologies such as three-way catalysts, gasoline particulate filters (GPF), diesel oxidation catalysts (DOC), diesel particulate filters (DPF), and SCR systems.
• Experience with CAE analysis related to structural durability, vibration, fatigue, and thermal performance is desirable.

• Capability to contribute to the development of innovative exhaust system technologies that improve vehicle integration, durability, and manufacturing efficiency.
• Knowledge of TWC, GPF, DOC, DPF and SCR systems.
• Durability, vibration and fatigue analysis experience.
• Strong customer-facing communication and project leadership abilities.
• Advanced Analytical Skills: Ability to analyse complex data and make informed decisions based on analysis.
• Adaptability and Flexibility: Willingness to adapt to changing project requirements and environments.
• Innovative Mindset: Capability to contribute to the development of cutting‑edge thermal solutions through creative thinking.
• Leadership Abilities: Experience or potential to guide project teams and inspire collaboration among stakeholders.
• Strong Organizational Skills: Proficiency in managing multiple projects and deadlines efficiently.
• Continuous Learning Initiatives: Enthusiasm for staying updated with the latest industry trends and technologies.
• Experience with Lean or Six Sigma Methodologies: Knowledge in optimizing processes and improving quality control.
• International Project Experience: Experience working on international projects or with international teams could be beneficial.

• Develop exhaust system concepts and support customer technical reviews from sourcing through launch.
• Ensure compliance with customer specifications, emissions regulations, durability requirements, and packaging constraints.
• Support prototype builds, validation testing, root cause investigations, and product optimization activities.
• Work closely with global engineering teams and manufacturing facilities to support successful industrialization and launch activities.
• Lead and Manage Projects: Successfully oversee engineering projects from start to finish, ensuring they are completed on time, within budget, and to the specified quality standards.
• Engage with Customers: Serve as the primary point of contact for customers, understanding their requirements and ensuring these are met or exceeded throughout the project lifecycle.
• Provide Technical Expertise: Offer technical support and expertise to both internal and customer teams, translating customer needs into accurate technical specifications.
• Innovate and Collaborate: Work with design and engineering teams to develop innovative solutions that align with customer needs and industry standards.
• Identify and Mitigate Risks: Proactively identify potential risks in projects and develop strategies to mitigate these to ensure successful project outcomes.
• Communicate Effectively: Maintain clear, consistent, and proactive communication with all stakeholders, including customers, team members, and management.
• Maintain Quality Standards: Implement and uphold quality management systems to ensure the project deliverables meet customer expectations.
• Follow Design Processes: Adhere to design release procedures and prepare necessary documentation for Design Review milestones, such as DFMEAs, design concept sheets, and risk assessments.
• Collaborate Onsite: Occasionally work with engineering staff at customer locations to develop designs, specifications, and requirements.

• Fast-paced yet supportive and high-performing international team with an inspiring ambition to transform the future of mobility.
• Support in onboarding and further training that will set you up with Marelli's speed.
• A hybrid work model, helping you to achieve work-life balance-combining the best of both spending time working remotely, benefitting from focus time, and purposeful co-creation time in the office.

Together, we will drive the world towards a safer, greener, and better-connected future.

Are you ready to make your mark, shape the future of the automotive industry, and drive the growth of the Green Technologies business?

Contribute to shaping the vehicles of tomorrow with your unique talents. We are inviting you to take the next steps.

Marelli is a global, independent technology partner to the automotive industry, with a strongand established track record in innovation and manufacturing excellence.

Joining the Marelli team means becoming a part of something bigger, a place where you can explore your potential, pioneer innovation, and grow.

We believe in enabling people to do their best work. Our cultural attributes - Drive Results, Accountable, Entrepreneurial, Inclusive, Innovative, and Aware - are the cornerstones of a new Marelli culture. Be part of it!

Discover our open positions and take the first step towards an exciting career in Marelli. Explore new horizons and unleash your potential. Join us today! Let's push the boundaries together. We aspire to shape future mobility dreams and turn them into reality.