Senior Mechanical Engineer

Position Summary

The Senior Mechanical Engineer is a technically focused engineering expert responsible for owning the analysis, design, and development of complex electro-mechanical systems and fabricated assemblies. This role is oriented toward deep technical problem-solving—applying rigorous engineering analysis, simulation, and design principles to deliver robust, manufacturable products that meet performance, reliability, and quality requirements. The Senior Mechanical Engineer serves as the primary technical authority on the engineering team, mentoring junior engineers, resolving difficult design challenges, and setting a high standard for analytical rigor and engineering craftsmanship. This position is not primarily oriented toward production floor management or field support; rather, it is focused on engineering excellence at the design and development stage.

Essential Duties and Responsibilities

Mechanical Analysis and Design

Lead the engineering analysis and design of complex mechanical and electro-mechanical assemblies, applying first-principles thinking and quantitative methods throughout. Key responsibilities include:

• Perform detailed engineering analysis including structural load calculations, material sizing, deflection analysis, pressure/vacuum calculations, and seal integrity analysis for enclosures, frames, panels, and weldment assemblies.

• Apply Finite Element Analysis (FEA) to evaluate and validate structural performance, stress concentrations, fatigue, and deformation under static and dynamic loading conditions—using results to drive design decisions and optimization.

• Design and analyze sealing systems for pressurized and vacuum/negative-pressure enclosures, including gasket selection, compression set calculations, groove geometry, surface finish requirements, and sealing force verification; apply knowledge of applicable standards (e.g., UL 2200) to constrain material and process selection appropriately.

• Evaluate airflow, ventilation, and pressure management within enclosed systems, analyzing fan curves, system resistance, pressure drop, and leakage paths to ensure adequate performance under operating conditions.

• Design mechanical interfaces—including door systems, latching mechanisms, hinges, and closures—with a rigorous understanding of tolerances, deflection, alignment, and the interaction between structural stiffness and sealing performance.

• Apply GD\&T (per ASME Y14\.5) to all design work, performing tolerance stack-up analysis to ensure that assemblies achieve required fit and function across the full manufacturing variation envelope.

• Conduct thermal analysis and design for heat management within enclosures, including convective and forced-flow cooling strategies appropriate to the application.

Sheet Metal, Weldment, and Fabrication Design

Design sheet metal components, weldments, and fabricated structures with a thorough understanding of manufacturing processes.

Key responsibilities include:

• Design sheet metal components and large structural weldments fabricated from carbon steel, stainless steel, and aluminum, with a deep understanding of material properties, forming limits, weld joint design, and fabrication-induced distortion.

• Apply DFM (Design for Manufacturability) and DFT (Design for Testability) principles throughout the design process, collaborating with manufacturing to ensure designs are producible using available processes including laser cutting, punch press, press brake forming, sawing, welding, grinding, blasting, painting, and assembly.

• Generate complete, high-quality manufacturing documentation including 2D assembly drawings, detail part drawings, flat patterns, cut lists, weld symbols, and DXFs using SolidWorks (with PDM).

• Develop and maintain Bills of Material (BOMs), hardware specifications, and work center routing tables in the company's ERP system.

• Use precision measurement tools—including calipers, micrometers, gauge blocks, height gauges, and gauge pins/plugs—to verify design intent; CMM experience is a plus.

Systems Integration and Electro-Mechanical Design

Develop integrated electro-mechanical systems with proficiency in mechanical-electrical interfaces. Key responsibilities include:

• Design electro-mechanical systems integrating mechanical enclosures, structural frames, and fabricated assemblies with electrical, control, and power systems components.

• Apply working knowledge of low-voltage electrical systems and their integration into mechanical assemblies, including enclosure penetration design, conduit routing, connector selection, and grounding/bonding requirements.

• Address acoustics, shock, vibration, and environmental protection requirements as applicable to the product design, performing analysis or testing as required to ensure compliance and reliability.

• Design hydraulic and pneumatic system interfaces and components where applicable, including manifold design, fitting selection, and system pressure management.

• Develop and execute design verification test plans; conduct or coordinate testing to confirm performance against requirements and document results in accordance with the QMS.

Technical Leadership and Mentorship

Serve as the primary technical resource and mentor for the engineering team. Key responsibilities include:

• Provide technical mentorship and direction to junior and mid-level engineers, reviewing drawings, analyses, and designs to raise the overall technical quality and engineering rigor of the team.

• Establish and promote best practices for engineering analysis, drawing standards, tolerance application, and design documentation across the engineering department.

• Conduct and lead formal design reviews (PDR, CDR) to evaluate technical readiness and identify risks before committing to production.

• Research and evaluate customer design proposals, specifications, and standards to assess feasibility, identify technical risks, and develop design requirements.

• Apply and interpret relevant industry codes and standards (including UL 2200, NEMA, ASME, IEEE, and others as applicable) to guide design decisions and ensure product compliance.

• Exercise independent technical judgment on engineering decisions; provide clear written and verbal communication of analysis results, design rationale, and recommendations to engineering, management, and customers.

• Adhere to and support the company's Quality Management System (QMS) and ISO 9001:2015 procedures, including participation in design change control, nonconformance resolution, and corrective/preventive action activities.

Required Qualifications

Required

• Master's degree in Mechanical Engineering strongly preferred; Bachelor's degree in Mechanical Engineering required.

• 8\+ years of progressive mechanical engineering experience in a manufacturing or industrial fabrication environment.

• Demonstrated expertise in structural and mechanical analysis, including load calculations, deflection analysis, and tolerance stack-up analysis.

• Hands-on experience with FEA tools (ANSYS, SolidWorks Simulation, Abaqus, or equivalent) applied to real design problems.

• Proven proficiency in sheet metal and weldment design for large-scale fabricated assemblies.

• Expert-level application of GD\&T per ASME Y14\.5\.

• Proficiency with SolidWorks 3D CAD and PDM (or equivalent enterprise data management); Microsoft Office Suite.

• Strong working knowledge of sealing system design, enclosure integrity, and pressure/vacuum environments.

• Experience with airflow and ventilation analysis in enclosed systems.

• Ability to read, write, and communicate effectively in English.

Preferred

• Professional Engineer (PE) license.

• Experience designing to UL 2200, NEMA, or equivalent electrical/power generation enclosure standards.

• Background in mechanical acoustics, vibration isolation, or shock analysis.

• Experience with hydraulic and pneumatic system design.

• Working knowledge of low-voltage electrical systems and electro-mechanical integration.

• CMM programming or coordinate measurement experience.

• Experience working within an ISO 9001 or AS9100 quality management system environment.

• Familiarity with ERP systems for BOM management, routing, and production documentation.

Work Environment

This position is primarily office-based within an engineering environment adjacent to the manufacturing production floor. The Senior Mechanical Engineer will conduct regular walkthroughs of the production floor to evaluate fabricated assemblies, observe manufacturing processes, and collaborate with production staff—requiring the ability to work safely in an industrial environment while wearing appropriate PPE as required in those areas. Physical demands include the ability to sit at a workstation for extended periods, walk throughout the facility multiple times daily, and safely lift, carry, push, and/or pull up to 35 pounds. Clarity of near vision sufficient to review detailed engineering drawings, computer displays, and precision measurement instruments is required. This is a full-time position working standard business hours, with occasional flexibility to support critical project milestones.

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