Mechanical Design Engineering Intern

We are seeking a Mechanical Design Engineer II to bring next-generation automotive lighting concepts to life. In this role, you will take hands-on ownership of physical enclosures, thermal management systems, optical packaging, and structural brackets. You’ll bridge the gap between initial napkin sketches and production-ready electro-mechanical assemblies. You won't just be pushing CAD models; you will be driving DFM, building prototypes, running stress simulations, and ensuring our products withstand the harshest off-road conditions imaginable. If you thrive in a nimble environment, love optimizing heat dissipation, and naturally find yourself dissecting hardware or customizing off-road rigs in your spare time, you’ll fit right in. Electro-Mechanical & Thermal Packaging • 3D CAD & Enclosure Design: Lead mechanical CAD development (SolidWorks) for rugged LED light housings, bezels, lenses, and mounting hardware. • Thermal & Environmental Shielding: Design high-performance heat sinks and thermal dissipation pathways for high-output LED arrays while sealing housings against dust and high-pressure washing (IP68/IP69K). • PCB & Optical Integration: Work closely with electrical engineers to integrate custom PCBs, wiring harnesses, lenses, and reflectors into tight mechanical footprints. Materials, Prototyping & DFM • Material Selection: Select optimal metals, engineered plastics, thermal interfaces, gaskets, and coatings to maximize strength, weight savings, and environmental resistance. • Rapid Prototyping & Testing: Build, assemble, and bench-test functional prototypes using 3D printing, CNC machining, and lab environmental testing. • Manufacturing Optimization: Design for Manufacturability/Assembly (DFM/DFA) across die-cast aluminum, injection molding, and sheet metal processes. OEM Execution & Quality Standards • Interpret, author, and validate mechanical drawing standards, tolerance stacks (GD&T), and technical specs for OEM clients. • Automotive Compliance: Ensure all mechanical assemblies comply with SAE/DOT standards, vibration/shock requirements, and thermal shock cycles. • Production Support: Partner with manufacturing teams and vendors to resolve tooling, tolerance, or assembly issues during initial production ramps. Education & Experience: Bachelor’s degree in Mechanical Engineering (BSME) or related field with 3–6 years of hands-on mechanical product design experience (preferably in automotive, lighting, or rugged electronics). • Solid CAD & GD&T Skills: Strong proficiency in 3D CAD design (SolidWorks) and practical application of GD&T (ASME Y14.Electro-Mechanical Design: Proven experience packaging electronics, thermal interfaces, optical optics, or die-cast aluminum/injection-molded components. • Experience interpreting, creating, and validating engineering specifications and drawings for OEM automotive applications. • Thermal & FEA Analysis: Fundamental knowledge of thermal simulation (CFD) and structural analysis (FEA) to validate designs prior to prototyping. Preferred / Bonus Points • Off-Road & Automotive Passion: Active involvement in the automotive or off-road community (overlanding, rock crawling, motorsports) is a huge plus—you understand the real-world abuse our gear faces. • Optical Packaging: Familiarity with secondary optical design, reflector geometry, or polycarbonate lens molding. • Experience working with overseas or domestic tooling vendors and machine shops. \nCompany Description Nacho Offroad Lighting is a manufacturer of aftermarket automotive lighting. We take pride in being off road enthusiasts and design products we are passionate about. In-house design, validation, and manufacturing with an aggressive roadmap of new products planned. Nacho Offroad Lighting is a manufacturer of aftermarket automotive lighting. We take pride in being off road enthusiasts and design products we are passionate about. In-house design, validation, and manufacturing with an aggressive roadmap of new products planned.