Sr. Mechanical Design Engineer

Overview

Position Overview

We are seeking a skilled Senior Mechanical Design Engineer to lead the design and development of sheet metal enclosures and electromechanical assemblies. This role combines creative design work with commercial responsibilities, requiring both strong technical capabilities and business acumen. The ideal candidate will excel at translating customer requirements into manufacturable designs while providing accurate cost estimates and quotes for custom and semi-custom solutions.

Key Responsibilities

Product Design & Development

• Design sheet metal enclosures, chassis, panels, and brackets using SolidWorks
• Develop complete electromechanical assemblies including structural components, hardware, wiring harnesses, and mounting solutions
• Create detailed manufacturing drawings with GD&T, bend allowances, material specifications, and finish requirements
• Design for manufacturability (DFM) considering fabrication processes including laser cutting, punching, forming, welding, hardware insertion, and finishing operations
• Optimize designs for cost, weight, thermal management, and assembly efficiency
• Conduct tolerance stack-up analyses and ensure proper fit and function of mating components
• Perform structural calculations and FEA analysis when required for load-bearing applications

Cost Estimation & Quoting

• Generate accurate cost estimates for custom and semi-custom sheet metal assemblies based on material costs, fabrication time, finishing processes, and purchased components
• Prepare detailed quotes including bills of materials (BOMs), labor hours, process routing, and pricing for customer proposals
• Collaborate with manufacturing and purchasing teams to validate cost assumptions and lead times
• Conduct make-vs-buy analyses for components and assemblies
• Support value engineering initiatives to reduce product costs while maintaining quality and functionality

Customer & Cross-Functional Collaboration

• Work directly with customers and sales team to understand application requirements, environmental conditions, performance specifications, and budget constraints
• Participate in design reviews and present concepts to internal stakeholders and customers
• Partner with manufacturing engineering to ensure designs are optimized for our fabrication capabilities and tooling
• Coordinate with quality assurance on inspection requirements and acceptance criteria
• Support prototype builds and first article inspections
• Provide technical support during production and address field issues as needed

Documentation & Standards

• Maintain accurate CAD models, drawings, and engineering change orders (ECOs) in PLM/PDM system
• Ensure designs comply with relevant industry standards (UL, NEMA, IP ratings, etc.) and customer specifications
• Create and maintain standard design guidelines and component libraries to promote design reuse
• Document design decisions, calculations, and test results

Required Qualifications

• Bachelor's degree in Mechanical Engineering or related discipline
• 5-7 years of experience in mechanical design with significant focus on sheet metal fabrication
• Proficiency in 3D CAD software (SolidWorks preferred) and 2D drawing creation
• Strong understanding of sheet metal manufacturing processes including laser cutting, turret punching, press brake forming, welding (MIG, TIG, spot), hardware insertion (PEM fasteners), and surface finishing (powder coating, plating, anodizing)
• Working knowledge of materials including various steel alloys, aluminum, stainless steel, and their properties
• Experience applying GD&T per ASME Y14.5 standards
• Strong problem-solving skills and attention to detail
• Excellent communication skills, both written and verbal

Preferred Qualifications

• Exposure to manufacturing cost estimation or quoting is a plus; candidates without direct quoting experience but with strong cost-awareness in design decisions (DFM, make-vs-buy input, vendor cost tradeoffs) are encouraged to apply — this responsibility will grow over time in the role
• Experience with FEA tools (SolidWorks Simulation, ANSYS, or similar)
• Knowledge of thermal management design for electronic enclosures
• Familiarity with EMI/RFI shielding requirements and grounding techniques
• Experience with enclosure ratings (NEMA 1/12/4/4X, IP ratings)
• Background in design for high-volume manufacturing and assembly automation
• Understanding of electrical/electronic packaging and cable management
• Experience with PLM/PDM systems (Windchill, Teamcenter, or similar)
• Knowledge of industry standards: UL, CSA, CE marking requirements

Key Competencies

• Strong analytical and mathematical skills for structural and cost calculations
• Ability to balance technical excellence with commercial realities and cost constraints
• Detail-oriented with strong organizational skills for managing multiple projects
• Customer-focused mindset with ability to translate requirements into practical solutions
• Collaborative team player who works effectively with manufacturing, purchasing, and sales
• Self-motivated with ability to work independently and drive projects to completion
• Adaptable and comfortable working in a fast-paced environment with changing priorities

Technical Environment

• CAD Software: SolidWorks (primary), AutoCAD
• Analysis Tools: SolidWorks Simulation or equivalent FEA package
• PLM/PDM: Product data management system for revision control
• ERP Integration: Interfacing with ERP system for BOMs and costing
• MS Office Suite: Excel for cost analysis, Word for documentation, PowerPoint for presentations

Working Conditions

This position is primarily office-based at our Sterling, MA headquarters with regular visits to the manufacturing floor to review prototypes, assess production feasibility, and support process improvements. Some travel to customer sites or supplier facilities may be required (estimated 5-10%).

What We Offer

• Opportunity to see your designs come to life in our state-of-the-art fabrication facility

• Collaborative environment with direct access to manufacturing experts

• Variety of projects across multiple industries and applications

• Comprehensive benefits package including medical/dental/vision coverage, 401(k) with company match, holidays and paid time off, eligibility for Long Term Investment Plan (LTIP)

You should be proficient in:

• Project Management
• CAD Software
• Design for Manufacturability (DFM)
• Design for Assembly (DFA)
• Mechanical Design & Engineering
• Product Design Experience
• Sheet Metal Design & Fabrication