Staff R&D Mechanical Engineer

Staff R&D Mechanical Engineer
Houston,
TX77029
Posted: 07/21/2026
Employment Type:
Permanent
Category: EngineeringJob Number: 29740Pay Rate: $110,000 - $125,000 AnnuallyWork Setting: HybridJob DescriptionTitle: Staff R&D Mechanical Engineer
Location: Houston, TX (Hybrid | Onsite 4 days per week, can pick work from home day)
Job Type: Permanent
Compensation: $110,000 - $125,000 Annually
Industry: Electrical Manufacturing
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About the Role
Our client, a global leader in electrical connection, protection, and infrastructure solutions, is seeking a Staff R&D Mechanical Engineer to join their product development team in Houston, Texas. This organization designs innovative products that help protect critical equipment, facilities, and industrial processes across a wide range of industries worldwide.
In this senior-level engineering role, you will lead the development of new products and technologies with a strong emphasis on mechanical design, non-metallic materials, and product innovation. You will collaborate with cross-functional teams throughout the product development lifecycle, helping drive projects from concept through validation, certification, and commercialization. This position offers the opportunity to influence product strategy, support technology roadmaps, and contribute to a culture focused on innovation and continuous improvement.
Travel: Up to 10% domestic travel.

Job Description
As a Staff R&D Mechanical Engineer, you will play a critical role in developing innovative products that support critical electrical infrastructure and industrial applications. This position combines technical leadership, hands-on engineering, and cross-functional collaboration to bring new products from concept to commercialization. Working closely with global engineering, manufacturing, quality, compliance, and product management teams, you will drive product innovation, validate performance, optimize manufacturability, and help shape future technology strategies that enhance product reliability, quality, and customer value.
Participate in global product development teams, working closely with manufacturing engineering, supply chain, quality, compliance, and product management stakeholders.
Lead and support prototype development, testing activities, and external certification efforts, including hands-on engineering support when necessary.
Guide engineering simulations and analyses, including FEA and FMEA, to validate product performance, reliability, and design effectiveness.
Define and coordinate validation plans, laboratory testing, and performance evaluations.
Collaborate with internal and external fabrication partners to develop practical, scalable, and cost-effective manufacturing processes.
Design, develop, and improve both new and existing products in alignment with business and product development strategies.
Establish engineering best practices and design standards that optimize performance, quality, reliability, manufacturability, and cost.
Support continuous improvement initiatives and contribute to technology development across multiple teams and functions.
Serve as a subject matter expert for product technologies, supporting product portfolio planning and long-term technology roadmaps.
Ensure compliance with applicable industry standards, certifications, and regulatory requirements.

Qualifications
Required Qualifications:
Bachelor's degree in Mechanical Engineering, a related engineering discipline, or equivalent combination of education and experience.
8+ years of mechanical design experience, preferably supporting new product introduction (NPI) and product development initiatives.
Strong experience working with non-metallic materials and components.
Demonstrated knowledge of polymer and non-metallic material behavior, including:
Thermoformed components
Elastomeric seals and gaskets
Fiber-reinforced and composite materials
Experience selecting materials based on:
Mechanical performance requirements
Environmental exposure conditions
Flammability considerations
Chemical resistance
UV exposure and aging characteristics
Understanding of Design for Manufacturing (DFM) and Design for Assembly (DFA) principles for plastic components, including:
Draft angles
Wall thickness requirements
Ribbing design
Tolerancing practices
Tooling tradeoffs
Familiarity with manufacturing processes for non-metallic products, including molding, extrusion, bonding, over-molding, and assembly operations.
Experience navigating applicable regulations, certifications, and industry standards related to non-metallic product design.
Ability to work collaboratively within cross-functional and global engineering teams.
Preferred Qualifications:
Advanced experience leading new product development and commercialization efforts.
Experience supporting globally distributed engineering and manufacturing organizations.
Hands-on experience with product testing, validation, and certification programs.
Familiarity with electrical infrastructure, industrial, or equipment protection products.
Experience developing engineering standards, design guidelines, and technology roadmaps.
Knowledge of reliability engineering methodologies and continuous improvement practices.

Benefits
Our client offers eligible full-time employees a comprehensive benefits package designed to support their health, well-being, financial security, and work-life balance. Benefits may include medical, dental, and vision insurance; flexible spending accounts; short-term and long-term disability coverage; critical illness and accident insurance; life insurance; a 401(k) retirement plan with company match; and an employee stock purchase plan with company match. Additional supplemental benefits may include tuition reimbursement, caregiver leave, personal and parental leave, back-up care services, paid time off including volunteer time, well-being programs, and legal and identity theft protection.

How to Apply
Take the first step on your new career path!To submit yourself for consideration for this role, simply click the apply button and complete our mobile-friendly online application. Once we’ve reviewed your application details, a recruiter will reach out to you with next steps!

Equal Opportunity Statement
As an equal opportunity employer, Dahl Consulting welcomes candidates of all backgrounds and experiences to apply. If this position sounds like the right opportunity for you, we encourage you to take the next step and connect with us. We look forward to meeting you!
Dahl Consulting is proud to offer a comprehensive benefits package to eligible contract employees that will allow you to choose the best coverage to meet your family’s needs. For details, please review our Benefits Summary: . Dahl Consulting is an Equal Opportunity Employer and does not discriminate in employment on the basis of race, color, religion, sex (including pregnancy and gender identity), national origin, political affiliation, sexual orientation, marital status, disability, genetic information, age, membership in an employee organization, retaliation, parental status, military service, or other applicable legally protected characteristics.Review DAHL & earn up to $100 | Refer a friend for rewards | Share This Job: to save this search and get notified of similar positions.

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About Houston, TX
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