BIW Design Engineer / BIW Structure Engineer – Job Description

Position - BIW Design Engineer / BIW Structure & Layout Engineer

Department - R&D

Reporting To - BIW Manager / BIW Lead

Job Summary

The BIW Design Engineer will be responsible for complete BIW structure development, BIW

layout preparation, manufacturable design release, and compliance management for vehicle

body systems. The role includes concept development, CAD design, packaging feasibility,

DFM/DFA/DFS activities, GD&T implementation, manufacturing coordination, cost optimisation,

and ensuring structural, dimensional, and quality targets are achieved.

The engineer must work closely with CAE, manufacturing, tooling, quality, supplier, and vehicle

integration teams to ensure robust BIW development from the concept stage to production.

Key Responsibilities

1. BIW Structure Development

-Develop and design BIW structures including:

-Underbody

-Side body

-Roof structure

-Front end structure

-Rear end structure

-Door structure

-Closures

-Reinforcements

-Cross members

-Mounting brackets

-Ensure structural integrity, crashworthiness, stiffness, durability, and weight optimisation.

-Support platform commonisation and carry-over strategy.

-Maintain proper load paths and section strength.

2. BIW Layout Preparation

Prepare a complete BIW layout and package feasibility.

Define:

-Section concepts

-Joining strategy

-Master sections

-Datum schemes

-Tooling direction

-Assembly feasibility

-Spot weld accessibility

Ensure proper packaging clearance with:

-Chassis

-Powertrain

-Interior

-Electrical systems

-HVAC

-Exterior trims

3. GD&T and Dimensional Engineering

-Apply proper GD&T as per ASME/ISO standards.

Define:

-Datum structures

-Tolerance stack-up

-Functional dimensions

-Critical characteristics

-Support dimensional variation analysis and quality improvement.

-Ensure fixture and check feasibility.

-Coordinate with CMM and quality teams.

4. DFM

Ensure manufacturable sheet metal design, considering:

-Drawability

-Wrinkle prevention

-Thinning control

-Springback

-Split line feasibility

-Tool accessibility

-Bead and emboss feasibility

-Corner relief standards

-Hemming feasibility

-Review forming simulation and resolve manufacturability concerns.

-Coordinate with die design and stamping teams.

-Ensure production feasibility for high volume manufacturing.

5. DFA

Ensure easy and robust assembly process.

Improve:

-Weld gun accessibility

-Assembly sequence

-Robot reachability

-Fastener accessibility

-Part locating strategy

-Foolproofing features

-Reduce assembly complexity and cycle time.

-Support assembly line validation and trial build activities.

6. DFS

-Ensure service-friendly BIW interfaces.

-Maintain accessibility for repair and replacement.

-Support body repair strategy and service requirements.

-Ensure compliance with field repair standards.

7. Material and Manufacturing Knowledge

Good understanding of:

-CR steel

-GI steel

-High-strength steel (HSS)

-AHSS

-Aluminum applications

Knowledge of:

-Material thickness selection

-Weldability

-Corrosion protection

-Surface treatment

-Joining methods

Understanding of:

-Spot welding

-MIG welding

-Laser welding

-Riveting

-Adhesive bonding

8. BIW Compliance & Regulations

Ensure compliance with:

-Crash regulations

-Durability targets

-NVH targets

-Manufacturing standards

-Vehicle packaging standards

-Support homologation and certification activities.

9. CAD and PLM Responsibility

Create and manage:

-3D CAD models

-2D drawings

-Assembly structures

-BOM release

-Engineering change management

-Maintain PLM documentation and release process.

-Support design reviews and engineering documentation.

10. CAE and Simulation Coordination

-Coordinate with CAE teams for:

-Crash analysis

-Durability analysis

-NVH analysis

-Forming simulation

-Modal analysis

-Implement CAE feedback into design improvements.

11. Quality & Supplier Coordination

-Work with supplier quality teams for:

-Part quality improvement

-Weld quality

-Dimensional quality

-Manufacturing concerns

Support:

-Trial builds

-Line audits

-Root cause analysis

-Corrective actions

Required Skills

-Strong BIW engineering fundamentals

-Good understanding of automotive sheet metal design

-Strong GD&T knowledge

-Knowledge of DFM/DFA/DFS principles

-Understanding of manufacturing processes and tooling

-Knowledge of welding and joining methods

-Understanding of crash and durability requirements

-Good problem-solving capability

-Cross-functional coordination skills

-Strong analytical and communication skills

Software Knowledge

-Preferred knowledge in: CATIA V5

Experience Requirement

-Experience in automotive BIW design and development

-Experience in production vehicle development preferred

-Experience in sheet metal and assembly design

-Knowledge of tooling and manufacturing process validation

Engineer-BIW