Headquarters: Penn Yan New York
URL: http://www.coachandequipment.com
Located in the beautiful Finger Lakes region of New York state, Coach and Equipment has been one of the best bus builders in America for over 75 years. After 52 years with us, one of our engineering team members will be retiring and we will be adding a new position for our team! We are seeking a:
Senior Design Engineer – Surface Modeling & Thermoforming Tooling
Position Summary
Coach & Equipment is seeking a seasoned Senior Design Engineer with deep expertise in surface modeling using SolidWorks and thermoformed part design, focused on commercial vehicle body components. This position is critical to the design and production of bus and specialty vehicle bodies that are aesthetically refined, aerodynamically optimized, and cost-efficient to manufacture.
The ideal candidate will lead the development of plastic and composite exterior and interior components, ensuring manufacturability and long-term durability in demanding fleet and transit environments. Expertise in managing imported surfaces and tooling tolerances specific to large-format thermoforming is essential.
Key Responsibilities
Product & Surface Modeling
· Create complex and production-ready surface models for bus and vehicle body panels in SolidWorks.
· Translate conceptual surfaces into manufacturable designs with appropriate draft, wall thickness, and mounting features.
· Ensure models integrate seamlessly with chassis structures, subframes, and adjacent systems.
Thermoformed Part Design
· Design large thermoformed components such as wheel arches, body cladding, and interior panels.
· Collaborate with tooling vendors and in-house fabrication teams to ensure mold accuracy, vacuum paths, temperature regulation, and cycle time optimization.
· Incorporate mold flow principles and post-forming tolerance requirements into designs.
Surface Repair & Data Optimization
· Evaluate and repair imported surface models (STEP, IGES) from third-party design sources.
· Reconstruct or replace incomplete or low-quality surface data to meet high cosmetic and dimensional standards.
· Maintain surface continuity and curvature critical to professional-grade automotive finishes.
Cross-Functional Collaboration
· Partner with industrial designers and supply chain teams to deliver integrated vehicle body solutions.
· Provide engineering support during prototype builds, form trials, and production launches.
· Generate and approve production-ready drawings and documentation including BOMs and GD&T.
Required Qualifications
· Bachelor’s Degree in Mechanical Engineering, Industrial Design Engineering, or related field.
· 5+ years of design experience in commercial vehicle, specialty vehicle, or automotive body manufacturing.
· Advanced expertise in SolidWorks surface modeling.
· Proven success designing for heavy-duty thermoforming in transportation applications.
· Skilled in repairing imported surfaces and working with complex CAD data.
· Knowledge of automotive body assembly techniques, fasteners, adhesives, and coatings.
· Familiarity with FMVSS and ADA regulations is a plus.
Preferred Qualifications
· Experience working with bus, truck, or van body components.
· Understanding of material behaviors of ABS, TPO and other thermoformable plastics.
· Background in structural reinforcement integration (e.g., bonded metal inserts, subframe interfaces).
· Exposure to ERP-linked BOM management and PLM systems.
Soft Skills
· High attention to detail with a focus on cosmetic and functional excellence.
· Effective communicator with cross-functional teams including manufacturing and vendors.
· Able to manage multiple priorities under tight production timelines.
· Curious, adaptive, and driven to continuously improve product quality and tooling efficiency.
What We Offer includes:
· Competitive salary and incentive bonus programs
· Health, dental, vision, and disability insurance
· 401(k) with employer contribution
· Paid time off and holidays
· Professional development opportunities
· Be part of a team shaping the future of sustainable, durable, and efficient transportation
For a virtual tour of Coach please click on the careers tab on our website www.coachandequipment.com
To be considered for this opportunity, please submit your resume to hr@coachandequipment.com
We look forward to hearing from you!
Leave a Reply