Design Engineer Interview: Key Questions and Expert Answers to Secure Your Dream Job

Are you preparing for a design engineer interview?  

The path to securing a role in this field goes beyond showcasing your skills on a resume.  

This blog dives into real-world interview questions that design engineers face, providing refined answers and insights to help you stand out in your next interview. 

The design engineer interview process can seem daunting, but being prepared with clear, well-thought-out answers can give you the edge you need.  

 Ready to ace your interview? Let’s dive into the key questions!

Why is the tail section of cars in Western countries longer compared to the ones in the Indian market? 

The tail section in Western cars is often longer due to design preferences, different safety regulations, and larger trunk space requirements. In India, compact cars are more popular due to narrower roads, parking constraints, and fuel efficiency demands. 

2. What are the various pillars of a BIW (Body in White) model? 

The main pillars in a BIW model are the A-pillar (supports windshield), B-pillar (supports roof structure between front and rear seats), C-pillar (supports rear window), and D-pillar (in some vehicles, supports the rear of the vehicle). 

3. What are the parameters to be considered during a frontal crash test? 

Important parameters include the speed of impact, structural integrity, crumple zones, airbag deployment, seatbelt performance, and occupant protection. These factors help evaluate vehicle safety. 

4. What are the different types of plastics and their processes? 

Plastics are categorized into thermoplastics and thermosetting plastics. Common processes include injection molding, blow molding, extrusion, and rotational molding, each suited for different applications. 

5. List the steps in a product development cycle. 

The product development cycle includes concept design, feasibility analysis, prototyping, testing, production, and product launch. 

6. What is the most intricate part of designing any part/model? 

The most intricate part is balancing functionality, manufacturability, and cost-effectiveness. Ensuring that the design meets performance requirements while being easy to manufacture and within budget is a key challenge. 

7. How do you decide the parameters for the quality criteria? 

Parameters for quality criteria are based on factors such as material properties, design requirements, safety standards, and manufacturing processes. These ensure the product meets necessary performance and safety standards. 

8. What is the significance of preprocessing for structural analysis for a Stepney floor panel? 

Preprocessing involves preparing the model for analysis by defining the mesh, boundary conditions, and material properties. It ensures the structural analysis is accurate and reflects real-world behavior under stress. 

9. Some cars are lighter than others in the market, so how do you decide on weight reduction or addition and on which parts? 

Weight reduction is often achieved by using lighter materials like aluminum or composites for non-load-bearing parts. Parts like the hood, doors, and fenders are typically targeted for weight reduction while maintaining structural integrity. 

10. What is the significance of the fender in a BIW model? 

The fender protects the vehicle from road debris, mud, and stones. It also contributes to the vehicle's aerodynamics and structural rigidity, particularly in crash scenarios. 

11. What is wiring harness and routing? 

A wiring harness is a bundle of cables and wires that transmit electrical power and signals throughout the vehicle. Routing refers to the organized path through which these cables are laid out in the vehicle. 

12. Explain chemical potting. 

Chemical potting is a process used to encapsulate electronic components in a protective resin, providing insulation, moisture resistance, and protection against shock and vibration. 

13. What is the difference between resolution and accuracy? 

Resolution refers to the smallest measurable increment in a system, while accuracy is the degree to which the measurement matches the true value. High resolution does not always mean high accuracy. 

14. If the client gives you a connector part (shown on the screen), what will be your next step as a Design Engineer? 

I would first analyze the connector's design specifications, check for compatibility with the overall system, and ensure it meets functional and safety requirements before proceeding with any design modifications or approvals. 

15. What are the components of a cable and list the materials used and why? 

A cable typically includes conductors (copper or aluminum for high conductivity), insulation (PVC for flexibility and insulation), shielding (aluminum foil for interference protection), and a jacket (rubber or PVC for protection). 

16. What is resistance, and how do we test the resistance of the given cable? 

Resistance is the opposition to the flow of electric current. We test it using an ohmmeter or multimeter to ensure the cable’s integrity and performance. 

17. What is the difference between force and inertia? 

Force is an external influence that causes an object to accelerate, while inertia is the property of an object to resist changes in its motion. 

18. Why do we use a clutch in a vehicle? 

A clutch is used to disengage the engine from the transmission, allowing the driver to shift gears smoothly without stopping the engine. 

19. What is the significance of using multiple gears in a transmission? 

Multiple gears allow the vehicle to operate efficiently at different speeds. Lower gears provide more torque for acceleration, while higher gears reduce engine load for fuel efficiency at cruising speeds. 

20. What are the types of gears? 

Common types of gears include spur gears, helical gears, bevel gears, and worm gears. Each type is used based on the mechanical advantage needed in the system. 

21. What is a governor? 

A governor is a mechanical device used to regulate the speed of an engine by controlling the fuel supply, maintaining a steady and safe operating speed. 

Conclusion: 

In the field of design engineering, mastering technical concepts and understanding industry-specific practices is essential to securing a role.  

Questions like the ones provided above are designed to test not only your theoretical knowledge but also your practical application of skills.  

Preparing for these topics will put you in a strong position to ace your next design engineer interview and build a successful career in this ever-evolving field. 

With Skill-Lync's Post Graduate Programs, you'll build a rock-solid foundation in all these critical concepts, making you interview-ready in no time. Plus, our Career Experts offer hands-on support through mock interviews, resume workshops, LinkedIn profile optimization, and much more! 

Sign up for a FREE course demo today, and let’s start your journey toward landing that dream job!