Mechanical Design Engineer II

Job Description

The Role

We are seeking a Mechanical Design Engineer II to bring next-generation automotive lighting concepts to life. In this role, you will take hands-on ownership of physical enclosures, thermal management systems, optical packaging, and structural brackets. You’ll bridge the gap between initial napkin sketches and production-ready electro-mechanical assemblies.

You won't just be pushing CAD models; you will be driving DFM, building prototypes, running stress simulations, and ensuring our products withstand the harshest off-road conditions imaginable. If you thrive in a nimble environment, love optimizing heat dissipation, and naturally find yourself dissecting hardware or customizing off-road rigs in your spare time, you’ll fit right in.

Key Responsibilities

Electro-Mechanical & Thermal Packaging

• 3D CAD & Enclosure Design: Lead mechanical CAD development (SolidWorks) for rugged LED light housings, bezels, lenses, and mounting hardware.

• Thermal & Environmental Shielding: Design high-performance heat sinks and thermal dissipation pathways for high-output LED arrays while sealing housings against dust and high-pressure washing (IP68/IP69K).

• PCB & Optical Integration: Work closely with electrical engineers to integrate custom PCBs, wiring harnesses, lenses, and reflectors into tight mechanical footprints.

Materials, Prototyping & DFM

• Material Selection: Select optimal metals, engineered plastics, thermal interfaces, gaskets, and coatings to maximize strength, weight savings, and environmental resistance.

• Rapid Prototyping & Testing: Build, assemble, and bench-test functional prototypes using 3D printing, CNC machining, and lab environmental testing.

• Manufacturing Optimization: Design for Manufacturability/Assembly (DFM/DFA) across die-cast aluminum, injection molding, and sheet metal processes.

OEM Execution & Quality Standards

• OEM Technical Specs: Interpret, author, and validate mechanical drawing standards, tolerance stacks (GD&T), and technical specs for OEM clients.

• Automotive Compliance: Ensure all mechanical assemblies comply with SAE/DOT standards, vibration/shock requirements, and thermal shock cycles.

• Production Support: Partner with manufacturing teams and vendors to resolve tooling, tolerance, or assembly issues during initial production ramps.

Qualifications & Skill Set

• Education & Experience: Bachelor’s degree in Mechanical Engineering (BSME) or related field with 3–6 years of hands-on mechanical product design experience (preferably in automotive, lighting, or rugged electronics).

• Solid CAD & GD&T Skills: Strong proficiency in 3D CAD design (SolidWorks) and practical application of GD&T (ASME Y14.5).

• Electro-Mechanical Design: Proven experience packaging electronics, thermal interfaces, optical optics, or die-cast aluminum/injection-molded components.

• OEM Spec Mastery: Experience interpreting, creating, and validating engineering specifications and drawings for OEM automotive applications.

• Thermal & FEA Analysis: Fundamental knowledge of thermal simulation (CFD) and structural analysis (FEA) to validate designs prior to prototyping.

Preferred / Bonus Points

• Off-Road & Automotive Passion: Active involvement in the automotive or off-road community (overlanding, rock crawling, motorsports) is a huge plus—you understand the real-world abuse our gear faces.

• Optical Packaging: Familiarity with secondary optical design, reflector geometry, or polycarbonate lens molding.

• Supplier Coordination: Experience working with overseas or domestic tooling vendors and machine shops.