Sr. Applications Engineer

Dana Incorporated’s Light Vehicle Thermal Division designs and manufactures powertrain-agnostic, advanced thermal management solutions for the rapidly evolving mobility landscape. We are seeking a Senior Application Engineer to lead the design, development, and launch of heat exchangers for next-generation internal combustion, hybrid, and electric powertrain vehicles.

In this role, you will drive customer-facing development programs from concept through validation and into production launch for major automotive OEMs and Tier 1 suppliers. You will manage prototype resources, mentor junior engineers, and collaborate with a global, multi-disciplinary team to deliver high-performance technologies that enable efficient, sustainable vehicle platforms.

Main Responsibilities

Program Launch & Technical Leadership

• Launch programs autonomously by gathering customer requirements and engaging cross-functional teams for quoting, feasibility assessments, and other related reviews from conception through launch
• Lead formal design reviews and approve engineering drawings for prototype and production readiness.
• Manage prototype workflows, including resource allocation, components procurement, assembly oversight, and on-time delivery. Hands-on effort may be required from time to time.
• Supervise, mentor, and coach student interns, associate engineers, and developing engineers.

Customer Engagement & Communication

• Lead technical discussions with global customers through both virtual and in-person meetings.
• Deliver technical presentations to customers regarding specific product architectures, performance data, and engineering challenges.
• Prepare and perform DFMEA reviews to ensure specific application requirements and environmental conditions are fully met.
• Translate customer specifications directly into comprehensive Design Verification Plan and Report (DVP&R) documents.

APQP, Financials, & Process Management

• Execute APQP processes by driving specific planning steps, documentation, and stage-gate compliance.
• Navigate financial stage-gates, providing cost estimations for prototypes, engineering development, and testing (ED&T), and costed BOMs.
• Prepare technical inputs for RFIs and RFQs, delivering accurate performance predictions and sizing assessments.
• Support validation testing to guarantee product durability, quality, and strict regulatory compliance.

Innovation & Problem Solving

• Lead problem-solving activities utilizing structured tools (e.g., 8D, Fishbone, 5 Whys) to resolve complex engineering issues.
• Advance heat exchanger designs with innovative concepts that optimize performance, weight, and cost efficiency.
• Drive continuous improvements in two-phase prediction methods, development processes, and analytical tools.

Qualifications

• University degree in Mechanical or Chemical Engineering.
• Experience in heat transfer and/or fluid systems. 2-phase flow experience is an asset.
• Minimum 5 years experience launching automotive programs from concept to production. Experience working with major OEMS like Ford/GM/Stellantis etc. is an asset.

• Strong knowledge of sheet metal forming, brazing, and machining limitations.
• Experience with APQP, project financials, prototype costing, and stage-gates.

• Advanced data-analysis skills using Python, MATLAB, or similar tools.
• Structured problem-solving capability using standard engineering root-cause tools.
• Excellent English communication skills for global customer presentations and mentoring.
• Legally able to live and work in Canada