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Dimensional Variation Engineer/ DVA (3DCS) - Contract
📍 Surrey (Hybrid) | ⏳ Contract 6 Months (Outside IR35)
We are supporting a leading automotive OEM in the search for an experienced Dimensional Variation Engineer (DVA) with strong 3DCS tolerance analysis expertise to support the delivery of a new vehicle programme.
This role plays a critical part in ensuring vehicle-level dimensional quality, supporting concept validation, gap & flush performance, and robust dimensional control from early concept through to engineering release.
The Role
As a Dimensional Variation Engineer, you will apply 3D Design Variation Analysis (DVA) techniques to validate multiple vehicle concepts and ensure the optimal complete vehicle solution is delivered against aesthetic, functional and quality targets.
Working closely with Perceived Quality, Design, Manufacturing and Vehicle Engineering teams, you will help define and govern the vehicle dimensional control strategy across both exterior and interior systems.
Key Responsibilities
- Apply 3D Design Variation Analysis (DVA) methods to validate vehicle concepts and architectures
- Build and maintain 3DCS tolerance simulation models to assess design capability
- Analyse simulation results and generate clear reports against vehicle gap, flush, aesthetic and functional targets
- Support and influence the definition of vehicle-level gap & flush targets in collaboration with the Perceived Quality team
- Provide Engineering Release (ER) sign-off across all components for new model programmes
- Work cross-functionally to define a robust dimensional control concept, evaluating both product and process capability
- Attend design reviews to share lessons learned, highlight dimensional risks, and recommend optimal design solutions
- Raise validated dimensional concerns through the client's faults management system
- Develop strong understanding of component manufacturing processes and best-practice tooling philosophies
- Provide input into manufacturing assembly sequence and assembly concept decisions
- Ensure FT&A and GD&T are applied correctly and in line with BS8888 / ISO 1101, supporting downstream manufacturing processes
- Support the creation of datum strategy concepts (using GD&T) for jigs, fixtures and measurement plans
- Own and maintain internal standards and training guides for 3DCS model creation
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Essential Skills & Experience
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- Demonstrable experience using 3DCS Tolerance Analysis software for vehicle-level DVA
- Strong background in dimensional engineering, tolerance analysis and variation reduction
- Solid understanding of GD&T, FT&A and their application to BS8888 standards
- Experience delivering dimensional quality within new product development programmes
- Methodical, analytical approach with strong problem-solving skills
- Ability to work cross-functionally and influence engineering decisions
Desirable Experience
- Degree in Mechanical / Automotive Engineering (2:1 or above) or equivalent experience
- CATIA V5 experience
- Knowledge of 8D / Practical Problem Solving (PPS)
- Experience across a wide range of materials and processes including:
- Composites
- Polymer mouldings
- Pressed steel / aluminium sheet metal
- Castings and laminates
- Understanding of jig and fixture design concepts
- Basic knowledge of SPC, statistics and process capability
- Automotive OEM or Tier 1 experience
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