System Design Engineer

AVL Test Systems, Inc. is seeking a System Design Engineer to join our Emissions Design Services team. The System Design Engineer is responsible for the design, integration, and technical execution of advanced emissions measurement and test systems supporting automotive, heavy-duty, non-road, aerospace, and emerging powertrain applications.

Working within a multidisciplinary engineering team, the System Design Engineer develops complete emissions laboratory and test cell solutions that meet customer requirements, regulatory standards, and project objectives. This includes defining system architectures, specifying equipment and instrumentation, developing technical documentation, and ensuring seamless integration of emissions measurement systems with facility, automation, electrical, mechanical, and safety subsystems.

The System Design Engineer serves as the technical owner of complex emissions testing projects and is responsible for one or more subsystems throughout the project lifecycle. Responsibilities include managing technical interfaces between emissions analyzers, sample handling systems, dilution tunnels, particulate measurement equipment, automation systems, facility utilities, and customer-owned equipment while balancing engineering cost, quality, and schedule objectives.

The role collaborates closely with project managers, applications engineers, controls engineers, electrical and mechanical designers, and commissioning teams to ensure successful implementation and operation of the complete test solution. The System Design Engineer also supports system integration, troubleshooting, verification, validation, and customer acceptance activities, ensuring that delivered systems achieve required performance, accuracy, and compliance with applicable emissions testing standards.

Work Location & Travel

• This position follows a hybrid work arrangement, allowing a combination of remote and office-based work.
• Engineers are expected to periodically support onsite project activities, including system integration, commissioning, and customer acceptance testing.
• Customer projects are primarily located in Michigan and the Midwest; therefore, occasional travel to customer locations may be required based on project needs.
• Typical travel is expected to be less than 25%.

Applicants must have the unrestricted authorization to work in the United States on a full-time basis. Employer will not sponsor an applicant for a work visa for this position.

RESPONSIBILITIES:

• Design and develop emissions testing systems and laboratory solutions for engine, powertrain, vehicle, and component testing applications.
• Define system architectures, equipment specifications, and technical requirements based on customer needs and regulatory requirements.
• Develop and review system layouts, process and instrumentation diagrams (P&IDs), functional descriptions, and technical documentation.
• Coordinate technical interfaces between emissions measurement equipment, automation systems, facility infrastructure, and test cell subsystems.
• Support equipment selection, procurement, factory acceptance testing, commissioning, and site acceptance activities.
• Troubleshoot system design and integration issues and develop effective technical solutions.
• Support verification and validation activities to ensure system performance and compliance with applicable industry standards.
• Collaborate with project teams to manage technical risks, engineering schedules, and project deliverables.
• Provide technical guidance to customers, suppliers, and internal stakeholders throughout project execution.

QUALIFICATIONS/SKILLS:

Experience & Education

• 3–5+ years of relevant engineering experience.
• Bachelor’s degree in Chemical Engineering or a related engineering discipline; equivalent experience may be considered.
• Master’s degree in Engineering preferred.

Technical Knowledge

• Strong understanding of fluid dynamics, heat transfer, thermodynamics, and chemical process calculations.
• Experience with dew point analysis, air flow characterization, pressure loss calculations, duct sizing, calibration methods, and mass/chemical balance calculations.
• Knowledge of Fourier Transform Infrared (FTIR) spectroscopy and emissions measurement principles is a plus.
• Familiarity with automotive emissions regulations, testing standards, and laboratory quality systems, including ISO 9001 and ISO 17025, is a plus.
• Understanding of mechanical, electrical, controls, automation, and facility infrastructure systems used in test laboratories.

Industry Experience

• Experience with emissions measurement systems, engine or vehicle testing, laboratory design, test cell integration, or related engineering applications.
• Working knowledge of emissions analyzers, particulate measurement systems, dilution systems, sample handling systems, and associated instrumentation.
• Automotive experience, particularly with combustion engine, hybrid, or alternative powertrain technologies, is preferred.

Professional Skills

• Strong systems engineering and analytical problem-solving abilities.
• Ability to troubleshoot complex technical issues and develop practical solutions.
• Effective communication and collaboration skills for working across multidisciplinary engineering teams.