Mechanical Integration Engineer

Location: Foster City, CA

We're looking for a highly self-sufficient engineer who can operate as a hybrid Harness / Mechanical Integration Engineer to enable fast, safe, and serviceable implementation of low-voltage electrical systems in vehicles. This role bridges harness routing/retention and mechanical packaging, focusing on practical solutions such as brackets, clips, clamps, channels, strain relief, and protective features to ensure electrical components and harnesses can be installed reliably in real vehicles.

The ideal candidate can independently take loosely defined integration problems, drive the design to a manufacturable solution, and support prototype builds with minimal guidance.

Responsibilities

• Own end-to-end harness mechanical integration for assigned vehicle areas: define routing/retention strategy, identify constraints, and drive implementation through release and build support
• Independently design and iterate mechanical retention solutions for harnesses and LV components (brackets, clamps, clips, tie features, channels, grommet interfaces, protective covers, strain relief) with clear installation intent
• Lead packaging and routing studies in-vehicle: measure, model, manage clearances, avoid chafe/heat/sharp edges, ensure service access, and account for build variation and tolerance stack-ups
• Create complete CAD and release-ready documentation:
  • 3D CAD + 2D drawings for brackets/mounts/retainers (GD&T as needed)
  • Harness routing/retention definition and installation guidance sufficient for technicians and build teams
  • BOMs, fastener specs, torque requirements, and assembly steps
• Coordinate and support prototype builds / fit-checks and drive fast design loops to closure based on real vehicle feedback
• Proactively identify integration risks (rattles, loosening, chafe, interference, thermal proximity, ingress, accessibility) and implement prevention strategies
• Partner with EE, Vehicle System Integration, Vehicle Integration, Geometric Integration and Manufacturing to deliver stable, serviceable solutions

Qualifications

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, or related field with 5+ years' experience in automotive/robotics/aerospace or similar
• Demonstrated ability to work independently and deliver with minimal oversight
• Strong hands-on experience with harness routing/retention and/or mechanical packaging in constrained vehicle environments
• Proficiency with CAD (e.g., CATIA, NX, SolidWorks) and 2D drawings; comfortable driving designs through release/change control
• Solid understanding of DFM/DFA, tolerance stack-ups, and manufacturing methods (sheet metal, machining, injection molded clips, additive prototyping)
• Practical knowledge of harness integration best practices: bend radius, strain relief, branch management, clip spacing, chafe protection, heat avoidance, edge protection, grommet usage, service loops, installation sequencing
• Comfortable working directly with hardware, vehicles, and technicians in fast iteration cycles
• Strong communication and documentation skills

Bonus Qualifications

• Master's degree in Mechanical Engineering or Electrical Engineering
• Experience with harness design tools (e.g., Siemens Capital, CATIA/3DX, NX) and release workflows (PLM, ECO/CR)
• Familiarity with automotive networks and electrical integration constraints (CAN/LIN routing considerations, grounding, EMC-sensitive routing)
• Experience defining fastener strategy and durability considerations (vibration, corrosion, thermal, ingress/IP needs)
• Experience building or supporting test fixtures / special equipment for lab or vehicle work

Salary Range

• $110,000–120,000
• Actual salary dependent on experience, skills, and qualifications

Compliance Notice

Alten USA is a federal contractor and Equal Opportunity Employer. All candidates selected for employment must successfully complete a pre-employment drug screening as a condition of hire.