Senior Engineer

Lex Innovations is seeking an experienced Senior Engineer to support the full lifecycle of its power distribution products for defense contracts and programs. This position will serve as a key technical resource for sustaining and legacy engineering, build-to-print customer programs, design engineering, engineering documentation, and configuration management.

The Senior Engineer will work closely with customers, suppliers, Operations, Quality, Sales, and Product Development to resolve technical issues, improve existing products and documentation, and translate new customer requirements into manufacturable solutions. The ideal candidate is a hands-on mechanical engineer with strong product-design fundamentals, sound engineering judgment, and experience supporting products in a manufacturing environment.

Sustaining and Legacy Engineering

• Provide engineering support for existing and legacy products throughout their operational life.
• Investigate and resolve product, manufacturing, supplier, quality, and field-performance issues.
• Lead root-cause investigations and develop practical corrective and preventive actions.
• Evaluate component obsolescence, material substitutions, and alternate suppliers.
• Implement cost, quality, manufacturability, reliability, and serviceability improvements.
• Review proposed changes to ensure continued compliance with customer, regulatory, and product requirements.

Contract and Build-to-Print Engineering

• Serve as the primary engineering point of contact for assigned contract manufacturing and build-to-print programs.
• Review customer drawings, specifications, bills of material, and technical data packages for completeness and manufacturability.
• Identify technical risks, documentation conflicts, and missing or ambiguous requirements before production.
• Coordinate customer technical questions, requests for information, deviations, waivers, and drawing clarifications.
• Support prototype builds, first-article inspections, production readiness, and recurring manufacturing.
• Maintain clear technical alignment between customer requirements and internal production documentation.

Applications and Design Engineering

• Support new business opportunities by evaluating customer requirements and developing technically sound product solutions.
• Prepare or support technical concepts, layouts, product configurations, and cost-estimating inputs.
• Adapt existing product platforms to meet customer-specific application requirements.
• Contribute to the development of new products and scalable product platforms.
• Perform engineering calculations, tolerance analyses, material selections, and design reviews.
• Develop designs that balance performance, safety, cost, manufacturability, maintainability, and schedule.
• Provide technical support to Sales and customers throughout the proposal and order-development process.
• Create, review, and improve engineering drawings, specifications, bills of material, work instructions, and technical data packages.
• Correct incomplete, inconsistent, or outdated legacy documentation.
• Improve drawing quality, standardization, tolerancing, revision control, and design intent.
• Ensure documentation accurately reflects the approved product configuration and manufacturing process.
• Establish reusable design standards, templates, and engineering best practices.

Configuration Management

• Support and improve configuration-management processes across engineering and manufacturing.
• Create and process engineering change requests, engineering change orders, deviations, and related documentation.
• Maintain alignment among drawings, bills of material, specifications, ERP records, and released product configurations.
• Ensure changes are properly reviewed, approved, documented, communicated, and implemented.
• Maintain traceability of product revisions, customer-specific configurations, and approved substitutions.
• Help strengthen product-data governance and engineering release processes.

Cross-Functional Responsibilities

• Collaborate with Operations, Manufacturing Engineering, Quality, Supply Chain, Sales, and Product Development.
• Provide hands-on engineering support during prototype, pilot, and production builds.
• Communicate technical information clearly to engineering and non-engineering stakeholders.
• Manage multiple assignments and priorities while maintaining accountability for quality and schedule.
• Mentor less-experienced engineers, designers, and technical personnel as appropriate.
• Participate in design reviews, risk assessments, and continuous-improvement initiatives.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering or a closely related engineering discipline.

· 5 –15+ years of progressive engineering experience in manufacturing, aerospace, defense, electronics, or related industries.

• Strong proficiency in mechanical design, engineering drawings, tolerancing, materials, and manufacturing processes.
• Experience supporting products in a manufacturing or contract-manufacturing environment.
• Experience creating and maintaining bills of material, drawings, specifications, and engineering change documentation.
• Working knowledge of configuration management and formal engineering-release processes.
• Proficiency with 3D CAD and product-data-management or document-control systems.
• Strong problem-solving, organizational, and written and verbal communication skills.
• Ability to work directly with customers and translate technical requirements into actionable engineering solutions.

Preferred Qualifications

• Master’s in Mechanical Engineering or equivalent and a strong mechanical-design background.
• Seven or more years of relevant engineering experience.
• Experience with portable electrical equipment, power-distribution products, industrial equipment, electrical enclosures, cable assemblies, or other electromechanical systems.
• Familiarity with sheet metal, machined components, molded components, welded assemblies, and production tooling.
• Experience with design for manufacturability and assembly, tolerance analysis, root-cause analysis, and failure-mode analysis.
• Familiarity with electrical schematics, wiring diagrams, and basic electrical-system principles.
• Experience working with UL, NEC, military, government, or customer-specific technical requirements.
• Experience with ERP, PLM, PDM, or formal document-control systems.
• Experience supporting first-article inspection, supplier qualification, and production validation.

Job Requirements:

This position requires access to export-controlled information. Candidates must be a U.S. Person as defined by 22 C.F.R. §120.15 and/or may require licensure under ITAR/EAR.