Plastic Component Design Engineer — Fuse Box / Power Distribution Box & Wiring Harness Components

We’re looking for a Plastic Component Design Engineer specializing in Fuse Boxes, Power Distribution Boxes & Wiring Harness Components .

💼 Work model: 100% remote, with periodic trips to Sweden for project follow‑up meetings.

🌍 Eligible locations: Romania, Portugal, United Kingdom, France, Poland.

🧩 Industry: Automotive (Power Distribution, Fuse/Junction Boxes, Wiring Protection)

🔧 Tools: CATIA V5/V6 (preferred), NX, SolidWorks.

🪫 Domain expertise: Automotive wiring harness & electrical distribution systems.

⭐Role Description

The Plastic Component Design Engineer is responsible for the design, development, and release of injection-molded plastic components for automotive power distribution products — fuse boxes, junction boxes (JB/SJB), power distribution boxes (PDB), relay holders, fuse holders, connector housings, covers, brackets, and wiring harness protection components (channels, grommets, clips, conduits). The engineer owns the component from concept through production launch, ensuring designs meet electrical, mechanical, thermal, and manufacturability requirements.

🎯 Key ResponsibilitiesComponent Design (3D/2D)

• Develop 3D CAD models (CATIA V5/V6, NX, or SolidWorks) of plastic housings, covers, internal frames, bussed electrical center (BEC) trays, fuse/relay cavities, and terminal retention features.
• Design plastic-specific features: snap-fits, living hinges, locking lances, ribs, bosses, draft angles, uniform wall thickness, and CPA/TPA (connector/terminal position assurance) features.
• Design terminal cavity geometry ensuring proper terminal retention force, insertion force, and polarization/keying to prevent mis-assembly.
• Define sealing concepts (radial seals, mat seals, gaskets, interfacial seals) to achieve required IP ratings (e.g., IP67/IP69K for engine-compartment boxes).
• Create 2D drawings with full GD&T per ASME Y14.5, tolerance stack-up analyses, and critical-to-quality characteristics.
• Design harness attachment and routing interfaces: wire outlets, bundle strain relief, cover locks, bracket mounting to body-in-white, and clip/fir-tree fastening points.

Materials & Analysis

• Select engineering resins (PA66, PA6, PBT, PP, glass-filled grades) based on temperature class, creep, flammability (UL94), CTI/comparative tracking index, and cost targets.
• Ensure creepage and clearance distances between adjacent fuse/relay circuits meet electrical requirements; support thermal derating analysis of high-current paths.
• Run or interpret moldflow simulations (fill, warp, weld lines, sink marks) and structural FEA (snap-fit stress, vibration, drop, terminal retention) and iterate the design accordingly.
• Perform DFM/DFA reviews with mold makers: gate location, parting lines, ejection, slides/lifters, tool steel safety.

Validation & Quality

• Prepare and maintain DFMEAs; define and execute DVP&R (design verification plan) including thermal cycling, thermal shock, vibration, humidity, fluid resistance, and terminal push-out testing per OEM specs (USCAR-2, LV214, GMW, Ford ES).
• Support prototype builds (SLA/SLS, soft tooling), first-shot tool trials, dimensional layout reviews, and root-cause analysis of molding defects (short shots, flash, warpage).
• Support PPAP/APQP deliverables and engineering change management (ECR/ECN).

Cross-Functional & Supplier Work

• Interface with wiring harness design teams to ensure box packaging, wire bundle entry, and in-vehicle routing/serviceability (fuse access, labeling, cover removal clearance).
• Work with OEM customers on packaging studies, master sections, and design reviews; negotiate technical requirements.
• Coordinate with tooling suppliers and molding plants on quotes, tool timing, and launch support; participate in cost reduction (VA/VE) workshops.

✅ Requirements

• Bachelor's degree in Mechanical, Plastics, or Electrical Engineering.
• 3–5+ years designing injection-molded plastic parts, preferably automotive electrical components (connectors, junction boxes, fuse/relay centers).
• Proficiency in CATIA V5/V6 (or NX/SolidWorks) for solid and surface modeling and 2D drawings.
• Working knowledge of injection molding processes, mold construction, and design-for-molding rules.
• Familiarity with automotive connector/terminal systems, wiring harness architecture, fusing and power distribution concepts.
• Knowledge of GD&T, tolerance stacks, DFMEA, DVP&R, and APQP/PPAP.

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What’s waiting for you at ALDIA? ✨

ALDIA is an international IT and Engineering consultancy driving digital transformation across sectors like automotive, energy, petrochemicals, software, Big Data, and cybersecurity. With offices in Spain, France, the UK, Switzerland, and Sweden, it delivers specialized technical talent and tailored solutions that boost competitiveness and sustainable growth. Its multidisciplinary teams work closely with clients to solve complex challenges and improve operational efficiency. Professionals at ALDIA collaborate on cutting‑edge tech projects in a dynamic, innovation‑focused environment with strong career‑development opportunities. The company promotes a culture of collaboration, continuous learning, and meaningful impact.

🤝 Global Expertise

Join an international team of software specialists working across diverse industries. You’ll tackle real technical challenges, collaborate with experts, and grow in an environment where learning never stops.

🌍 Inclusion Without Exceptions

Everyone belongs here. Your identity, background or gender never define your opportunities. Your talent does. We’re committed to gender equality and diversity because innovation happens when people feel respected, valued and free to be themselves.

🚀 A Challenge Worth Your Talent

If you care about technical excellence, teamwork and continuous improvement, this is your kind of environment.

If you want to grow in a company that lives and breathes innovation, we’d love to hear from you.