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Senior Mechanical Design Engineer

Job Summary

The Senior Mechanical Design Engineer is responsible for leading the design, development, validation, and continuous improvement of mechanical products, systems, and manufacturing solutions. This role combines advanced engineering expertise with technical leadership, providing guidance and mentorship to engineering team members while driving projects from concept through production. The Senior Mechanical Design Engineer collaborates cross-functionally with manufacturing, quality, supply chain, and program management teams to deliver innovative, cost-effective, and reliable solutions that meet customer and business requirements.

Essential Duties and Responsibilities

• Lead the design and development of complex mechanical components, assemblies, and systems from concept through production release.
• Create, review, and approve engineering drawings, models, specifications, and technical documentation using SolidWorks and PDM systems.
• Provide technical leadership and mentorship to Mechanical Design Engineers, Drafters, and Engineering Technicians, promoting engineering best practices and professional development.
• Lead design reviews and ensure compliance with engineering standards, quality requirements, and applicable industry regulations.
• Perform engineering analysis including tolerance stack-ups, material selection, failure analysis, manufacturability assessments, and design optimization.
• Develop innovative design solutions that improve product performance, reliability, manufacturability, and cost efficiency.
• Research, design, evaluate, test, install, operate, and maintain mechanical products, equipment, systems, and processes to meet project requirements.
• Analyze customer requirements, specifications, and technical proposals to determine design feasibility, cost implications, and maintenance considerations.
• Coordinate with manufacturing teams to support prototype builds, production launches, process improvements, and troubleshooting activities.
• Investigate equipment failures, product issues, and manufacturing challenges; identify root causes and implement corrective actions.
• Develop and execute test plans, validation protocols, and engineering studies to verify design performance and reliability.
• Recommend and implement design modifications to improve functionality, eliminate system malfunctions, and enhance product quality.
• Specify system components and materials to ensure compliance with performance, safety, and regulatory requirements.
• Collaborate with suppliers, customers, and internal stakeholders to resolve technical issues and support product development initiatives.
• Lead multiple engineering projects simultaneously, managing schedules, priorities, risks, and deliverables.
• Support continuous improvement initiatives through application of Lean Manufacturing, Design for Manufacturability (DFM), Design for Assembly (DFA), and cost-reduction methodologies.
• Prepare and present technical reports, design reviews, and project status updates to management and stakeholders.
• Establish and maintain engineering standards, procedures, and documentation practices.
• Perform other duties as assigned.

Qualifications

Education

• Bachelor's Degree in Mechanical Engineering or Mechanical Engineering Technology required.
• Master's Degree in Mechanical Engineering or related field preferred.

Experience

• Minimum of 8-10 years of progressive mechanical design engineering experience in a manufacturing, industrial, or product development environment.
• Demonstrated experience leading engineering projects from concept through production implementation.
• Previous experience providing technical leadership, mentoring, or direct supervision of engineers and technical staff.
• Strong experience with mechanical system design, product development, and manufacturing processes.

Required Technical Skills

• Expert-level proficiency in SolidWorks and Product Data Management (PDM) systems.
• Strong knowledge of GD&T, tolerance analysis, and engineering drawing standards.
• Experience with Design for Manufacturability (DFM) and Design for Assembly (DFA) principles.
• Knowledge of materials, fabrication methods, machining, sheet metal, welding, and assembly processes.
• Experience with engineering analysis tools and methods, including FEA and root cause analysis.
• Strong understanding of manufacturing processes, quality systems, and continuous improvement methodologies.

Licenses / Certifications

• Professional Engineer (PE) License required.
• Additional industry certifications are a plus.

Leadership Competencies

• Proven ability to lead, mentor, and develop engineering team members.
• Strong project management and organizational skills.
• Ability to influence cross-functional teams and drive technical decisions.
• Effective facilitator of design reviews and engineering problem-solving activities.
• Demonstrated ability to balance technical excellence with business objectives.

Core Competencies

• Technical Leadership
• Mechanical Design & Product Development
• Complex Problem Solving
• Critical Thinking
• Engineering Analysis
• Decision Making
• Project Management
• Cross-Functional Collaboration
• Communication & Presentation Skills
• Continuous Improvement
• Time Management
• Customer Focus