Mechanical Design Engineer

Education: Bachelor's or Master's Degree in Mechanical Engineering Position Summary Client is seeking an experienced Mechanical Engineer to design ruggedized, mobile communication products intended to operate in extreme environments. The ideal candidate will have hands-on experience designing IP-rated enclosures, plastic components, die castings, and sheet metal parts using 3D CAD tools, preferably PTC Creo. The role also involves developing detailed engineering drawings for prototypes, fabrication, and tooling, along with performing thermal and structural simulations using Finite Element Analysis (FEA) tools. A strong theoretical foundation in heat transfer, structural mechanics, and mechanical system design is essential. Key Responsibilities Design ruggedized, IP-rated enclosures, seals, and gaskets to meet IP54 and higher ingress protection standards. Design plastic components for injection molding, metal components for die casting, sheet metal parts for stamping and fabrication, and CNC-machined components using 3D CAD systems (PTC Creo 8 or later preferred). Perform hands-on fabrication and assembly of prototype components using rapid prototyping techniques, including 3D printing, SLA, CNC machining, and prototype tooling. Generate detailed engineering drawings for PCBs, board assemblies, EMI shields, mechanical enclosures, cable assemblies, and fabrication/tooling. Evaluate mechanical systems and assemblies for structural integrity through classical static and dynamic calculations. Design lightweight mechanical structures for drone aviation applications, including magnesium cast components. Perform heat transfer calculations using fundamental heat transfer principles and equations. Conduct thermal and structural simulations using Finite Element Analysis (FEA) tools to optimize product size and weight. Apply Design for Manufacturability and Assembly (DFMA) principles throughout the product development lifecycle. Perform Design Verification Testing (DVT) using vibration, shock, and temperature cycling profiles based on standards such as MIL-STD-810. Develop EMI/RFI shielding solutions using advanced techniques, including robotic shield-can placement, EMI gaskets, and housing metallization. Review 3D CAD interfaces between electrical board design (ECAD) and mechanical design (MCAD) to identify and resolve component interference issues. Develop board constraint inputs for electrical board design. Prepare engineering reports, deliver presentations, and participate in design reviews. Create and maintain Bills of Materials (BOMs) and perform product cost analysis. Own mechanical design activities from initial prototyping through final production, collaborating with and managing external vendors. Required Qualifications Bachelor's or Master's degree in Mechanical Engineering. 5+ years of relevant mechanical engineering experience. Proficiency in 3D CAD tools such as PTC Creo or SolidWorks; Creo 8 or later is preferred. Strong theoretical and practical knowledge of: Mechanical systems and structural mechanics. Solid mechanics. Heat transfer and thermal analysis. Hands-on experience with Finite Element Analysis (FEA) tools for thermal and structural simulations. Experience designing mechanical components for manufacturing processes such as injection molding, die casting, sheet metal fabrication, and CNC machining. Strong communication, collaboration, and problem-solving skills. Ability to work effectively in a cross-functional engineering environment. #J-18808-Ljbffr