Senior Thermal Engineer - Refrigerant Heat Exchanger Development

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 Thermal Engineer to lead the design, development, and autonomous launch of refrigerant-based heat exchangers for next-generation automotive heat pump systems.

In this role, you will drive customer-facing development programs from concept through validation and into production launch. 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:

The ideal candidate would:

• University degree in Mechanical or Chemical Engineering.
• Expertise in heat transfer, fluid systems, and two-phase refrigerants.
• Proven track record launching automotive programs from concept to production.
• 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.

Why Join Us?

🌟 Competitive salary & benefits package.
📈 Career growth opportunities in a dynamic manufacturing environment.
⚙️ Work with cutting-edge quality systems and improvement methodologies.
👥 Be part of a collaborative and forward-thinking team.

 The expected annual base salary range for this role is $ 90,000- 100,000 CAD.

This job is for a new position .

The actual base salary offered to the successful candidate may vary based on multiple factors including but not limited to, individual's expertise  and level of experience applicable to the role they are being offered.

Dana Canada is an equal opportunity employer, committed to providing employment accommodation in accordance with the Ontario Human Rights Code and the Accessibility for Ontarians with Disabilities Act. If contacted for an employment opportunity or testing, please advise Human Resources if you require accommodation.

We are an Equal Opportunity Employer and do not discriminate against any employee or applicant for employment because of race, color, sex, age, national origin, religion, sexual orientation, gender identity, status as a veteran, and basis of disability or any other federal, state or local protected class.

Unsolicited Resumes from Third-Party Recruiters

Please note that as per Dana policy, we do not accept unsolicited resumes from third-party recruiters unless such recruiters were engaged to provide candidates for a specified opening. Any employment agency, person or entity that submits an unsolicited resume does so with the understanding that Dana will have the right to hire that applicant at its discretion without any fee owed to the submitting employment agency, person or entity.