Seal Design Engineer (Automotive)

Role details

Job Summary

We are seeking an experienced Automotive Weatherstrip Profile Design Engineer to lead the development, section optimization, and vehicle integration of door-frame, primary and secondary body, and flush-door sealing systems. Key areas of focus include EPDM/TPV co-extruded profiles, molded corner-joint design, vehicle-level validation, and end-to-end technical ownership from concept through start of production (SOP).

The ideal candidate has experience with a leading North American Tier 1 sealing supplier and a hands-on background in electric-vehicle sealing programs.

Key Responsibilities

1. Seal Profile & Section Design

• Design and optimize EPDM/TPV multi-chamber, co-extruded weatherstrip cross-sections for door-frame and body sealing systems.
• Apply deep knowledge of EPDM/TPV physical, aging, and extrusion properties.
• Define sponge and solid-rubber construction, flocking layout, wall thickness, cavity architecture, and compression behavior.
• Perform compression load deflection (CLD) tuning to balance door-closing effort, sealing performance, and durability.

1. Corner / Joint Design & Integration

• Develop extruded-to-molded corner and joint geometry, lip transitions, and sealing continuity.
• Specify material compatibility, shrinkage compensation, and bonding requirements.
• Resolve common corner defects, including lip lifting, leakage, fitment, and appearance issues; collaborate with the injection-tooling team to ensure mold manufacturability and production quality.

1. FEA Simulation & Performance Optimization

• Execute seal-compression and contact-pressure simulations, along with virtual validation of door-closing force.
• Troubleshoot vehicle-level issues, including noise, vibration, and harshness (NVH) wind noise, water leakage, fitment, and durability degradation.

1. DFM & Manufacturing Feasibility

• Partner with extrusion-tooling and manufacturing teams to evaluate profile manufacturability, extrusion consistency, and co-extrusion stability.
• Provide design for manufacturability (DFM) recommendations and optimize cross-section geometry for mass production.

1. Vehicle Program Technical Ownership

• Own sealing-system development from concept and prototype through trial build and SOP.
• Deliver design failure mode and effects analysis (DFMEA), design verification plan and report (DVP&R), bill of materials (BOM), and technical design documentation; support production part approval process (PPAP) and OEM customer sign-off.
• Lead 8D root-cause analysis for launch and field sealing issues in collaboration with quality and manufacturing teams.

1. OEM Technical Communication

• Participate in technical reviews with major North American OEMs, including design reviews, vehicle fit testing, and performance-validation alignment.

Qualifications

• 5+ years of automotive sealing-system design experience within Tier-1 suppliers
• Hands-on experience in door-frame weatherstrip profile design, EV flush-door sealing, and body-closure programs.
• Proven molded corner-joint design capability for multi-section extruded weatherstrips, including lip-transition geometry.
• Solid understanding of EPDM/TPV materials, sponge foaming, co-extrusion, and molded-corner processes.
• Proficiency in CATIA or NX for 3D profile and corner modeling; familiarity with seal-compression FEA workflows.
• Working knowledge of CLD tuning, door-closing force, wind noise, water tightness, and durability requirements.
• Familiarity with APQP, PPAP, DFMEA, DVP&R, and automotive quality-system standards.