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 pres