Flexible Sensor Design Engineer Jobs in Tennessee

Company Description

Flex-Tek, a division of Smiths Group, is a global manufacturing company serving aerospace, construction, thermal, industrial, and related manufacturing markets.

Job Description

The Flex-Tek Innovation Team is looking for an experienced Mechanical Design Engineer who wants to be part of a team driving broader automation, manufacturing technology, and innovation efforts across Flex-Tek businesses. This is a hands-on role for an engineer who enjoys turning real manufacturing challenges into practical, well-engineered solutions and likes to design, build, test, improve, and see their work make an impact. In this position, you will develop prototypes and machines, build CAD models and drawings, design tooling and fixtures, collaborate with controls and electrical team members, work with vendors, and help deliver reliable mechanical solutions across Flex-Tek sites that improve safety, quality, throughput, reliability, cost, and the company's ability to innovate faster.

Key Responsibilities:

• Design & Development
  • Design practical mechanical solutions for tooling, fixtures, guards, robot stands, material handling devices, and custom machine components.
  • Create and maintain 3D models, drawings, assemblies, layouts, configurable design files, and CAM-ready details using CAD software such as SolidWorks.
  • Perform basic engineering checks related to loads, force, torque, motion, clearances, tolerance, material selection, ergonomics, access, and structural integrity.
  • Select and apply commercially available components such as bearings, linear slides, pneumatic cylinders, motors, sensors, fasteners, framing, guarding, and purchased machine elements.
  • Design mechanical systems with automation and controls integration in mind, including sensor mounting, cable routing, pneumatic component placement, HMI access, electrical enclosure locations, robot tooling, guarding, operator stations, machine layouts, reach envelopes, and service clearances.

Project Execution & Shop Floor Support

• • Support prototype builds, 3D printed concepts, test rigs, fixture trials, equipment mockups, fabrication reviews, installation, troubleshooting, startup, validation, and production handoff.
  • Lead testing exercises for prototypes, fixtures, equipment changes, and process improvements; document test plans, catalog findings, summarize results, and recommend next steps.
  • Participate in design reviews, build reviews, risk assessments, troubleshooting discussions, and lessons-learned reviews to ensure designs meet project and production requirements.
• Documentation & Standards
  • Create and maintain build-ready drawings, models, BOMs, assembly notes, spare parts information, vendor quote packages, mechanical interface details, mounting provisions, and installation notes within document control processes.
  • Maintain organized design files, revisions, and project records so designs can be reused, supported, quoted, built, and transferred across Flex-Tek sites.
  • Apply company, safety, and industry standards when designing equipment, fixtures, guarding, access points, operator interfaces, and maintenance access.
• Cross-Functional Support
  • Gather requirements from internal customers, production teams, site leaders, and operators to understand the real operating need before beginning design work.
  • Coordinate with suppliers and fabrication partners to request quotes, clarify requirements, share CAD files, review manufacturability, and support build schedules.
  • Confirm purchased component compatibility before ordering, including complete part numbers, vendor models, cable requirements, pneumatic connections, mounting needs, lead times, and replacement availability.
  • Identify opportunities to improve existing equipment through design changes, standardization, simplification, reliability improvements, and better serviceability.
  • Help evaluate in-house build versus outsourced automation options by considering cost, lead time, manufacturability, assembly effort, controls complexity, maintainability, and long-term support.

Travel: 10-20%

Qualifications

Qualifications:

• Bachelor's degree in Mechanical Engineering, Mechanical Engineering Technology, or a related technical field.
• 3+ years of experience in mechanical design, manufacturing equipment, custom tooling, fixtures, automation support, or machine design.
• Proficiency in 3D CAD software, preferably SolidWorks, including assemblies, drawings, configurations, and revision control.
• Strong understanding of practical manufacturing processes such as machining, welding, sheet metal, fabrication, 3D printing, assembly, and purchased component selection.
• Hands-on mindset with a willingness to spend time on the shop floor, in the lab, and around equipment builds.
• Experience with mechanical systems that may include pneumatics, hydraulics, linear motion, conveyors, guarding, robotics support structures, or test equipment.
• Experience designing around automation components such as sensors, actuators, pneumatic valves, cable routing, electrical panels, robot tooling, and operator interfaces.
• Familiarity with GD&T, tolerance stack-up, and mechanical drafting standards.
• Strong problem-solving, communication, organization, and follow-through skills with the ability to manage multiple active design tasks.

Preferred Skills:

• Experience with machine safety, guarding design, ergonomic access, and equipment serviceability.
• Knowledge of motion systems, automation equipment, robot integration support, and how mechanical design affects controls integration.
• Exposure to rapid prototyping, 3D printing, test rigs, fixture trials, and practical shop-floor validation methods.
• Ability to collaborate with controls engineers during layout, design, build, debug, and startup so mechanical designs support sensors, actuators, HMI usability, PLC sequencing, safety circuits, pneumatic logic, access, maintainability, and troubleshooting.
• Familiarity with vendor coordination for automation components, including robot accessories, grippers, encoders, sensors, pneumatics, framing systems, and electrical enclosure hardware.
• Experience supporting robot or automated equipment layouts, including working envelopes, reach studies, part presentation, guarding, operator access, and maintainability.
• Comfortable supporting multiple Flex-Tek businesses and adapting designs to different products, processes, equipment types, and site constraints.

Additional Information

We believe that different perspectives and backgrounds are what make a company flourish. All qualified applicants will receive equal consideration for employment regardless of color, religion, sex, sexual orientation, gender identity, national origin, economic status, disability, age, or any other legally protected characteristics. We are proud to be an inclusive company with values grounded in equality and ethics, where we celebrate, support, and embrace diversity.

At no time during the hiring process will Smiths Group, nor any of our recruitment partners ever request payment to enable participation - including, but not limited to, interviews or testing. Avoid fraudulent requests by applying jobs directly through our career's website (Careers - Smiths Group plc)