Staff Mechanical Design Engineer

Staff Engineer – Equipment Design & Development 

Summary 

The Staff Engineer leads the design, specification, and deployment of advanced manufacturing equipment from concept through commissioning. This role is responsible for mechanical system architecture, vendor management, installation, and production ramp-up. The ideal candidate brings deep mechanical design expertise, automation knowledge, and hands-on experience with commissioning and acceptance testing to deliver scalable, reliable equipment solutions. 

Key Responsibilities 

• Lead mechanical system design and equipment architecture for automated manufacturing processes. 

• Develop equipment layouts, material flow paths, ergonomic considerations, and system interfaces. 

• Define performance metrics such as cycle time, precision, load capacity, and scalability. 

• Collaborate with automation, controls, and software teams for integrated system development. 

• Conduct engineering analysis including stress, thermal, and fluid modeling; perform DFM and DFMEA. 

• Translate requirements into technical specifications for custom or off‑the‑shelf equipment. 

• Evaluate vendors, lead design reviews, and validate compliance and performance. 

• Oversee installation, commissioning, FAT/SAT, troubleshooting, and root‑cause investigations. 

• Partner with process engineering on validation, predictive maintenance, and operational optimization. 

Qualifications 

• 7+ years in mechanical design, equipment development, or automation in high‑volume/advanced manufacturing. 

• Strong experience in mechanical systems, thermal/fluid dynamics, motion systems, and system integration. 

• Hands‑on experience designing, building, and commissioning manufacturing equipment. 

• Proficiency with 3D CAD (SolidWorks preferred) and FEA. 

• Knowledge of industrial automation, robotics, pneumatics, hydraulics, and safety systems. 

• Experience leading FAT/SAT and troubleshooting complex automation systems. 

• Knowledge of OSHA, NFPA, ISO, and industry safety standards. 

• Experience with procurement of complex, custom machinery. 

Preferred Skills 

• Experience with hazardous materials safety systems across chemical, energy, automotive, aerospace, or electronics industries. 

• Background in robotics, PLCs, mechatronics, or process development. 

• Familiarity with SCADA, IoT, and smart manufacturing platforms. 

• Expertise in GD&T and tolerance analysis. 

• Experience with Lean, Six Sigma, or process optimization.