Lead Mechanical Engineer

Precision Power Solutions (PPS) is a specialized division of EnerSys—a global leader in stored energy solutions for industrial applications. PPS focuses on cutting-edge energy solutions for the aerospace, defense, and medical industries . As we continue to grow, we’re looking for individuals who share a passion for these industries and want to be part of an innovative, dynamic team.

Certain positions at EnerSys Advanced Systems require access to information or technology that is subject to the International Traffic in Arms Regulations (ITAR) and other U.S. government security regulations. Candidates for these positions should be a “U.S. Person” under ITAR (U.S. citizen, lawful permanent resident, or a refugee/asylee) and/or otherwise comply with ITAR requirements for access rights to be considered for a position.

What We Offer:

• Generous Time Off – 3+ weeks of paid time off, plus 11 paid holidays
• Comprehensive Benefits – Medical, dental, and vision coverage for employees and dependents at a discounted rate
• Financial & Career Growth – Life insurance, short-term disability, educational reimbursement, flexible spending accounts, and an employee stock purchase plan
• 401(k) Matching – 100% match at a 6% contribution level
• Innovative Culture – We value excellence, teamwork, and long-term relationships with stakeholders, colleagues, and customers. Through innovative technology and ongoing training, we invest in our employees’ skills and career development.

At PPS, we don’t just build batteries – we power systems and devices that protect not only individual citizens but communities across the world.

If you’re excited about working in an innovative, fast-paced, high-tech environment, where your contributions make a real impact, we’d love to hear from you!

Job Purpose

The Lead Mechanical Engineer serves as the technical leader for the design, development, validation, and continuous improvement of advanced mechanical systems and products supporting commercial, industrial, and defense applications. This role leads complex engineering initiatives from concept through production, providing technical direction to engineering teams while collaborating closely with manufacturing, quality, supply chain, program management, and customers. The Lead Mechanical Engineer drives innovation, ensures compliance with applicable engineering standards, and develops reliable, manufacturable, and cost-effective solutions that meet demanding customer and operational requirements.

Essential Duties and Responsibilities

Essential Duties & Responsibilities

• Lead the mechanical design and development of complex products and systems from concept through production using advanced CAD software, including Autodesk Inventor, while ensuring compliance with ASME standards and engineering best practices.
• Serve as the technical lead on new product development initiatives, providing engineering guidance, reviewing designs, resolving technical challenges, and mentoring junior engineers throughout the product development lifecycle.
• Develop detailed 3D models, engineering drawings, assemblies, tolerance analyses, and Bills of Materials (BOMs) required for manufacturing, testing, and customer deliverables.
• Perform and oversee engineering analyses including finite element analysis (FEA), structural analysis, thermal modeling, vibration analysis, reliability assessments, and other simulation methods to validate design performance.
• Lead design reviews, engineering risk assessments, and failure investigations to ensure products meet performance, reliability, manufacturability, and quality objectives.
• Drive rapid prototyping efforts, coordinate laboratory and field testing, evaluate test data, and implement design improvements based on engineering analysis and customer feedback.
• Collaborate closely with Manufacturing Engineering, Operations, Supply Chain, and Quality teams to optimize products for manufacturability (DFM), assembly (DFA), cost, serviceability, and production scalability.
• Partner with suppliers and external engineering resources to evaluate components, resolve technical issues, and improve supplier performance related to quality, manufacturability, and delivery.
• Interface directly with customers to understand technical requirements, present engineering concepts, support design reviews, and resolve complex technical issues.
• Develop and maintain comprehensive engineering documentation including technical specifications, design reports, engineering change documentation (ECOs), validation reports, manufacturing instructions, and technical manuals.
• Ensure compliance with applicable industry standards, military specifications, customer requirements, and regulatory requirements throughout the product development process.
• Identify opportunities for new technologies, materials, manufacturing methods, and engineering tools that improve product performance, reliability, quality, and cost competitiveness.
• Provide technical mentorship and coaching to engineers and designers by reviewing work, sharing best practices, and promoting engineering excellence across the organization.
• Support proposal development, cost estimating, technical planning, and strategic engineering initiatives as required.

Qualifications

Required

• Bachelor's degree in Mechanical Engineering or a related engineering discipline.
• 8+ years of progressive mechanical design and product development experience in a manufacturing environment.
• Demonstrated experience leading complex mechanical design projects from concept through production release.
• Expert proficiency with Autodesk Inventor, SolidWorks, or equivalent 3D CAD software.
• Strong knowledge of ASME Y14.5 Geometric Dimensioning & Tolerancing (GD&T) and engineering drawing standards.
• Experience performing Finite Element Analysis (FEA), structural analysis, and engineering simulations.
• Experience designing products for manufacturability (DFM) and assembly (DFA).
• Experience developing production-ready engineering documentation, Bills of Materials, and Engineering Change Orders.
• Strong understanding of manufacturing processes including machining, fabrication, welding, sheet metal, casting, and assembly.
• Demonstrated ability to lead technical discussions, solve complex engineering problems, and influence cross-functional teams.
• Excellent written, verbal, and presentation communication skills.

Preferred

• Master's degree in Mechanical Engineering.
• Experience supporting defense, aerospace, or military programs.
• Experience with thermal management, heat transfer, and cooling system design.
• Experience with environmental qualification testing and reliability engineering.
• Knowledge of MIL-STD requirements and military specifications.
• Experience with Product Lifecycle Management (PLM) or Product Data Management (PDM) systems.
• Professional Engineer (PE) license.
• Project leadership experience in a matrixed engineering environment.

Competencies

• Technical Leadership
• Mechanical Design Excellence
• Systems Thinking
• Engineering Analysis
• Innovation & Continuous Improvement
• Project Execution
• Decision Making
• Problem Solving
• Customer Focus
• Cross-Functional Collaboration
• Coaching & Mentoring
• Communication & Influence
• Accountability
• Attention to Detail

General Job Requirements

• Generic

EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

We use artificial intelligence to screen, assess and select applicants for open positions, including for the purposes of reviewing and ranking application materials and scoring answers to application questions. Accordingly, decisions about your application and eligibility for employment with EnerSys may be made based exclusively on the automated processing of the personal information that you submit in your application materials.