Position Title Design Engineer
Alternate Title(s) Materials Engineer, Composite Engineer, Product Designer, Structural Engineer
Education & Training Level Bachelor’s degree required, graduate degree preferred
Education & Training Level Description Design engineers typically hold a bachelor’s degree or higher in electrical or mechanical engineering or a related discipline. Employers value practical experience, e.g., cooperative engineering programs, prior work experience, or internships. Design engineers often specialize in specific disciplines such as aerodynamics or electromechanical systems, so a master’s degree or Ph.D. in a specialized area will be advantageous. 
Brief job description Design engineers lead, perform, design and analyze wind turbine structures and components so that they efficiently generate the most power, are more reliable, withstand environmental stresses, have a lower cost, and reduced environmental impacts. They work on products throughout their entire life cycle, from conceptual design through design and development, testing, qualification, manufacturing, and installation and operation support. 
Preferred Level of Education Master’s degree
Preferred Level of Experience See the Bureau of Labor Statistics for more information.
Estimated/Expected Salary See the Bureau of Labor Statistics for more information.
Job Profile

Design engineers lead, perform, design and analyze wind turbine structures and components so that they efficiently generate the most power, are more reliable, withstand environmental stresses, have a lower cost, and reduced environmental impacts. They work on products throughout their entire life cycle, from conceptual design through design and development, testing, qualification, manufacturing, and installation and operation support.

When developing concepts for wind turbines and turbine systems, design engineers are responsible for the design, development and testing in order to prove function and reliability. They use computer software to develop virtual models of their designs, and evaluate the design in terms of function, safety, and cost to their customer. Design engineers test their designs and perform analyses, ensuring the product meets or exceeds requirements for design verification.

Wind turbines consist of thousands of parts, and each part must be designed to exact specifications so that they maximize performance and can withstand the stresses involved in generating wind power. Design engineers in the wind industry are continually working to improve the design, cost, feasibility of production and reliability of turbine components, structures and systems. They address issues and provide innovative solutions to blade design and wind tunnel testing, generator design and power control, tower and structural issues, mechanical and aerodynamic noise, blade pitch control and offshore installation and operation.

In addition to the initial design and testing of a wind turbine component, structure or system, design engineers also work with manufacturing and supply chain teams to ensure that the production of these parts are feasible and cost effective. Wind turbine manufacturers produce their products for fulfillment across the globe. Products must meet quality requirements as well as adhere to production cost and schedule guidelines.

When there is an issue with a product, the design engineer conducts a root cause failure analysis of the product to determine the source of the failure. If the failure is determined to be a design related cause, the design engineer works with engineering, manufacturing and supply chain teams to resolve the issue and prevent recurrence in production. They incorporate these lessons learned as well as best practices and standardization into drawings, specifications, design practices and processes for the company and industry.

In summary, design engineers typically do the following:

  • Plan and evaluate new projects, consulting with others to determine design requirements
  • Prepare proposals and budgets, analyze labor costs, write reports, and perform other managerial tasks
  • Supervise the work of designers, technicians, and other engineers and scientists
  • Use computer software to create drawings or virtual models of product designs
  • Create physical prototypes of their designs
  • Develop and direct the testing of designs, such as stress, load and fatigue testing of wind turbine blades
  • Monitor how materials perform and evaluate how they deteriorate
  • Conduct root cause failure analyses and develop solutions to prevent recurrence
  • Evaluate technical specifications and economic factors relating to the design objectives of processes or products
  • Examine materials and production costs to determine manufacturing requirements
  • Work with manufacturing and supply chain teams to improve product quality
  • Evaluate product safety and function to determine if a design meets requirements for design verification
  • Present designs and demonstrate prototypes.

Design Engineers use software such computer-aided design (CAD) or to computer-aided industrial design (CAID) to sketch ideas, make changes, develop models or create specific machine-readable instructions that tell other machines exactly how to build the product. 

Job Skills
  • Analytical skills. Design engineers must use logic or reasoning skills to study, recognize the need for, and design new products. When implementing a design, they need to be able to determine how materials will perform in a variety of conditions and how the materials must be structured to withstand those conditions.
  • Communication skills. In supervising technicians, technologists, and engineers, design engineers must be able to state concepts and directions clearly. When speaking with managers at high-level meetings, design engineers also must be able to communicate design concepts and provide status updates to people with varied backgrounds.
  • Creativity. Design engineers must be innovative. They imagine new designs and ways of implementing their products.
  • Problem-solving skills. Design engineers identify complex design problems, conduct root-cause failure analyses, and anticipate production issues. They then develop innovative design solutions, evaluate options, conduct tests, and implement solutions to meet timing, product cost and reliability targets.
  • Teamwork. Design engineers must be able to work with scientists, engineers and technicians from across their organization. They work together to ensure that product design, testing, manufacturing and deployment variables are addressed and any issues identified and resolved.
  • Technical skills. Design engineers must understand the technical aspects of how products work. They understand the principals of calculus and other advanced topics in mathematics for analysis, design, and troubleshooting in their work. 
  • Writing skills. Design engineers write reports to inform others about their design status and findings as well as develop plans and technical manuals that clearly, so that people without a technical background understand the concepts.
Resources

Bureau of Labor Statistics:

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