Product Development Engineer Intern Jobs in Texas

Product Development Engineer

On-Site  |  Full-Time  |  7–12 Years of Experience

Reports to: Director of Operations

Pay Range: $90,000–$120,000 per year, depending on experience

About the Role

Impact Recovery Systems is looking for an experienced Product Development Engineer to join our engineering team in San Antonio. This is a hands-on role for someone who is comfortable working independently, from concept through commercialization, on traffic safety and commercial products built from advanced polymers and metals. You'll own projects end-to-end: researching and specifying raw materials, building and testing prototypes, and working closely with manufacturing to bring designs into production.

What You'll Do

•      Design, develop, and test new products and product improvements for our traffic safety and commercial product lines, from concept through production launch.

•      Evaluate, select, and specify advanced polymer and metal raw materials based on mechanical, environmental, and cost requirements.

•      Build and test prototypes and functional samples; run and analyze physical testing to validate designs against performance and durability requirements.

•      Work hands-on in the lab and on the shop floor — building fixtures, running trials, and troubleshooting issues directly rather than delegating them.

•      Create and maintain drawings, specifications, and bills of material using CAD and PDM/PLM tools.

•      Partner with manufacturing, quality, and sourcing teams to resolve material and process issues and to support successful scale-up to production.

•      Manage multiple development projects simultaneously with minimal oversight, setting priorities and driving them to completion.

•      Investigate field and quality issues related to material performance and recommend corrective actions.

•      Stay current on new polymer materials, additives, and processing methods relevant to injection molding, rotational molding, and/or extrusion.

What You Bring

•      Bachelor's degree in Mechanical Engineering, Materials Science, Polymer Engineering, or a related field.

•      7–12 years of hands-on product development experience, ideally with products combining plastic/polymer and metal components.

•      Strong working knowledge of advanced polymer materials (e.g., HDPE, LDPE, PP, TPU, rubber compounds) and metals (e.g., steel, aluminum) and how material selection affects part performance, moldability, and cost.

•      Demonstrated ability to specify raw materials and work directly with suppliers on material selection and qualification.

•      Practical, hands-on approach — comfortable in a lab or plant environment, building and testing prototypes yourself.

•      Proven ability to work independently and drive projects forward without close supervision.

•      Proficiency with CAD software (SolidWorks preferred) and familiarity with FEA or other simulation tools.

•      Experience with injection molding, rotational molding, extrusion, or related manufacturing processes.

•      Strong problem-solving skills and solid understanding of DFM/DFA principles.

•      Experience in traffic safety, outdoor/UV-exposed products, or commercial products is a plus.

Compensation & Benefits

•      Medical, dental, and vision insurance.

•      401(k) with company match.

•      Paid holidays and vacation.

Why Impact Recovery Systems

Impact Recovery Systems has been designing and manufacturing traffic safety and protective guarding products since 1991. We offer a collaborative, hands-on engineering environment, competitive compensation, and the chance to see your work protect people and property in the real world.

Impact Recovery was founded in 1991 in San Antonio, Texas, and has grown into a thriving international organization. Expanding beyond roadways, today we manufacture high-performance products that help protect people and property around the world.