Additive Mechanical Design Engineer

Title: Mechanical Design Engineer – DMG MORI Additive Solutions Research and Development

Reports to: Design Lead

Location: DMG MORI Manufacturing USA, Davis, CA

Hours: Monday through Friday, 8:00am to 5:00pm

Classification: Exempt

Travel: 25%

This position has access to equipment and/or technology that is subject to U.S. export control restrictions. Hiring by DMG MORI must be made in compliance with applicable regulations.

The Mechanical Design Engineer will be responsible for the design, development, and optimization of mechanical systems for a state-of-the-art Laser Powder Bed Fusion (LPBF) additive manufacturing machine. This role involves creating innovative solutions for high-precision components, thermal management, powder handling, structural integrity and machine accuracy to ensure reliable and efficient machine performance. The engineer will collaborate closely with cross-functional teams, including electrical, software, and manufacturing teams, to deliver a robust product that meets stringent industry standards. This position requires a solid knowledge of engineering principles and additive production processes.

Essential Job Functions:

To perform this job successfully, an individual must be able to perform each essential function satisfactorily. The requirements listed below are representative of the knowledge, skills, and abilities required. Reasonable accommodation may be made to enable qualified individuals with disabilities to perform the essential functions. 

• Design and develop mechanical systems for LPBF additive machines, including structural frames, motion systems, powder handling mechanisms, optical and measurement systems
• Perform detailed CAD modeling and create engineering drawings for manufacturing
• Conduct engineering analysis to ensure system reliability under operational conditions
• Collaborate with cross-disciplinary teams to integrate mechanical designs with optics, electronics, and software systems
• Develop and validate mechanical prototypes through testing and iterative design improvements
• Specify materials and manufacturing processes suitable for high-precision, high-temperature and metal powder environments
• Ensure compliance with safety, regulatory, and quality standards throughout the design process
• Troubleshoot mechanical issues during assembly, testing, and at the customer site
• Manage investigation and countermeasures for product problem reports
• Manage design documentation, including BOMs, tolerance stack-ups, and revision control
• Support continuous improvement initiatives to enhance machine performance and reduce cost

Minimum Requirements: 

• Bachelor’s degree in Mechanical Engineering or related field (Master’s preferred)
• 2+ years of experience in mechanical design for complex machinery or precision equipment
• Proficiency in CAD and PLM software (CREO and Windchill preferred)
• Strong understanding of engineering for powder handling, laser/optical and motion control systems
• Experience with additive manufacturing processes or powder-based systems is highly desirable (LBPF preferred)
• Knowledge of GD&T and engineering drawing standards
• Familiarity with FEA tools for engineering analysis, computational fluid dynamics is a plus
• Excellent problem-solving skills and ability to work in a collaborative, fast-paced environment
• Knowledge of metal cutting, CNC programming, and additive manufacturing is preferred
• Proven flexibility with shifting priorities

Work Environment:

Exposure to manufacturing/machining environments which may present possible hazards such as noise, electricity, chemicals, heavy equipment, and other automated and manual machinery. General office environment experienced at DMG MORI office.

Physical Demands:

Frequent: Travel, operating a vehicle, standing, walking, bending, squatting, stooping, sitting, and reaching. Pushing, pulling, and lifting objects. Repetitive foot, leg, hand, arm, shoulder, and torso movements.

Periodic: Operating power equipment, sitting at a desk, utilizing computers and phones.

Occasional: Lifting or moving up to 50lbs.