Custom Machine Design - Senior Mechanical Engineer

Job Description

Job Description

Blast Cleaning Technologies, Inc. (BCT) is proud to be the leader in shot blast innovation! We are dedicated to our customers, resulting in continuous company growth year over year.

Why Work at BCT?

Highly Competitive Pay, Benefit Plans, & 401K: We pay for skill AND talent. We offer a full range of comprehensive benefits & 401K employer match up to 6%.

Medical Insurance: 90% of Insurance Premiums are covered by BCT!!! Low deductibles, ZERO coinsurance, & extensive provider networks to utilize.

Generous PTO & Paid Holidays: Take advantage of our generous PTO plans and many paid U.S. holidays.

Casual Work Environment: Enjoy a casual dress code and friendly workplace.

Historic Location: Work in our over $2 million investment in upgrades and refurbishment at our historic West Allis location.

Innovation: Work for a company that continuously invests back into the business and the employees. With our cutting-edge foundry being a prime example of true innovation.

Amenities: Enjoy free coffee, popcorn, summer cookouts, and more!

Continuous Education: Venture in your future with our tuition reimbursement program and our variety of investments in your continued learning.

Engaged Leadership: You will love AND know our CEO. Work with an ethical, hardworking, & interactive leader who listens to employees at all levels.

Second Chance Employer: If you have the skills and work ethic, we will give you a chance.

Onsite HR and IT Department: We provide dedicated onsite HR and IT support to ensure our employees' needs are met. We won't send you to a 1-800 number for help.

Veteran Support: BCT supports and honors veterans.

Made in America: All our components are made in the USA.

Our PACT Our core values (Passionate, Accountability, Customer-Focused, & Team Player) are rooted in the visionary spirit of our CEO, Carl Panzenhagen, who began his career as a teenager working in a foundry. As an adult, his extensive industry experience and dedication led him to create a company free from bureaucracy and grounded in ethical business practices. Guided by Carl’s leadership, a small team of five evolved into a self-sustaining manufacturing powerhouse. Today, BCT proudly stands 330+ employees strong and celebrates the completion of our cutting-edge foundry, a testament to our relentless pursuit of excellence and innovation.

Job Summary:
Under the direction of the Engineering Group Lead, the Senior Mechanical Engineer is a key technical leader responsible for the design, development, and delivery of custom, engineered‑to‑order industrial machinery. This role supports BCT’s mission of providing innovative, high‑performance custom equipment by translating customer requirements into robust mechanical solutions.

Beginning with the project kickoff, the Senior Mechanical Engineer leads mechanical design efforts including engineering calculations, 3D CAD modeling, and detailed machine layouts for complex custom assemblies. This position requires strong ownership of designs from concept through build, installation, and final performance, while collaborating closely with Applications Engineering, Controls, Manufacturing, Assembly, and Project Management.

Essential Duties and Responsibilities
This list of duties and responsibilities is not all-inclusive and may be expanded to include other duties and responsibilities as management may deem necessary from time to time.

Custom Machine Design & Engineering Leadership

• Serve as lead mechanical engineer on custom machine projects, collaborating with applications, manufacturing, assembly, and project management teams.
• Lead the conceptual development and detailed design of custom machinery, including mechanisms, frames, weldments, sheet metal, guarding, and system layouts.
• Apply sound mechanical engineering fundamentals and practical manufacturing knowledge (fabrication, welding, machining, assembly methods) to develop manufacturable, serviceable designs.
• Perform and review engineering calculations (loads, stresses, motions, tolerances, safety factors) to validate design performance and reliability.
• Own mechanical design intent and ensure consistency across models, drawings, and BOMs.
• Mentor and guide engineer I/II’s, providing leadership on design best practices, CAD standards, and problem‑solving approaches.
• Contribute to the development and maintenance of engineering standards, design guidelines, and reusable machine platforms

Project Execution

• Manage the mechanical engineering scope of assigned custom machine projects to meet cost, schedule, functionality, and quality objectives.
• Drive design reviews, risk assessments, and release milestones while maintaining alignment with customer requirements.
• Prepare and release complete engineering packages including 3D models, detailed drawings, bills of material, and supporting documentation.
• Communicate engineering status, technical risks, and design changes clearly to internal customers on a regular basis.
• Support continuous improvement by identifying opportunities to improve design efficiency, modularity, and manufacturability.

Cross‑Functional & Manufacturing Support

• Provide hands‑on support to Manufacturing by answering questions, resolving design issues, and issuing timely revisions.
• Collaborate closely with Electrical Engineering to ensure mechanical designs integrate seamlessly with automation systems (sensors, actuators, motion systems).
• Participate in or lead the creation of SOPs, standard machine elements, and common design libraries to streamline future custom projects.
• Partner with PMs to maintain schedule focus and support overall project execution.

Field & Customer Interaction

• Provide field support and occasional travel to assist with machine installation, commissioning, and troubleshooting.
• Participate in customer meetings and design reviews to present concepts, explain design decisions, and incorporate feedback into final solutions.
• Support root‑cause analysis and corrective actions for field issues or performance concerns.

Qualifications

• Strong expertise in SolidWorks or equivalent 3D CAD software for custom machine design.
• Proven ability to design engineered‑to‑order machinery that meets functional, budget, and schedule requirements.
• Experience designing mechanical systems that integrate with automation, motion control, and industrial controls.
• Excellent organizational skills with the ability to manage multiple priorities in a fast‑paced, project‑driven environment.
• Strong written and interpersonal communication skills with a collaborative, team‑oriented mindset.
• Proficiency with Microsoft Office; experience with project tracking tools such as MS Project or Smartsheet preferred.

Education and Experience

• Bachelor’s degree in mechanical engineering.
• 5–15 years of progressively responsible experience in custom machine design, industrial equipment, or engineered‑to‑order machinery, or an equivalent combination of education and experience.