Staff Mechanical Engineer

Staff Mechanical EngineerLocation: Duluth, GADepartment: Engineering & Product DevelopmentReports to: Hardware Engineering ManagerDirect Reports: NoneType: Full-TimeStatus: ExemptSchedule: Hybrid M-F (4 days in office; Friday remote)Salary: $120,000 - $140,000 + Bonus EligibleThe RoleWe're seeking a Staff Mechanical Engineer to serve as a technical authority in the design and development of complex mechanical systems — driving innovation from concept through production. This role offers the opportunity to own sophisticated mechanism design, lead cross-functional problem-solving, and deliver precision-engineered solutions that directly advance IPA's hardware capabilities. You'll be at the forefront of the product development lifecycle, ensuring every design is built to perform, manufactured to scale, and engineered with the end user in mind.What You'll DoLead research, development, and engineering projects from concept to production, with emphasis on complex mechanical systems, precision mechanisms, and advanced actuation solutions.Design and optimize multi-axis assemblies, precision linkages, gear systems, and actuation mechanisms using CAD tools (Solid Edge/SolidWorks), applying rigorous engineering analysis throughout.Apply DFM, DFA, and DFS principles at every stage of design — balancing mechanical performance with manufacturability, assembly efficiency, and long-term serviceability.Fabricate and test engineering prototypes, conducting motion analysis, simulation, and performance verification to validate designs before production commitment.Design manufacturing and assembly processes that meet cost, quality, safety, and schedule requirements, while developing assembly sequences that optimize efficiency and serviceability.Research and evaluate vendors and material sources for precision components and specialized manufacturing capabilities, from prototype through full production.Provide technical support and troubleshooting for in-house and vendor processes, supporting quality assessments, failure investigations, and root cause analysis of mechanical systems.Monitor project costs and report projections to Program Management, continuously optimizing designs to balance performance with cost-effective manufacturing.Travel: Up to 25%What You BringBachelor's degree in Mechanical Engineering, Electromechanical Engineering (or related field) with a minimum of 10 years of hands-on experience.Deep expertise in complex mechanism design — including kinematics, dynamics, multi-axis systems, and precision mechanical assemblies.Proficiency in 3D CAD modeling (Solid Edge preferred) and hands-on experience with fabrication techniques including sheet metal, injection-molded plastics, and conventional machining.Strong command of DFM, DFA, and DFS principles with a proven track record of translating design intent into production-ready solutions.Experience with motion simulation, FEA, kinematic analysis, and other advanced analysis tools for mechanism validation and optimization.Ability to source precision components, engage vendors for specialized manufacturing processes, and contribute to cost-saving redesigns without compromising performance.Strong communication and collaboration skills, with the ability to present technical concepts clearly to engineering teams, Program Management, and leadership.Familiarity with CNC machine tools, manual machining equipment (lathe, mill, drill press, grinder, belt sander, miter saw), pneumatic tools, and 3D printing for prototyping complex mechanical assemblies and precision components.Experience with hand tools and power tools for mechanism assembly, testing, and troubleshooting.Demonstrated working knowledge of electrical and electronic fundamentals as applied to electromechanical systems, including DC motors, solenoids, sensors, and switching devices; ability to read and interpret wiring diagrams and basic schematicsHands-on experience with prototyping and bench-level validation using microcontroller platforms such as Arduino to simulate, test, and iterate on hardware concepts prior to formal design releaseYou'll Excel If You:Thrive at the intersection of sophisticated mechanical design and real-world manufacturing constraints, and can confidently navigate complexity to deliver practical, elegant solutions.Are hands-on by nature — equally comfortable at a CAD workstation and on the shop floor, with a bias toward building and validating rather than theorizing.Take ownership of problems end-to-end, from identifying design risks early to seeing solutions through to production with precision and accountability.Bring a continuous improvement mindset, consistently challenging conventional design approaches and implementing innovative mechanical solutions that raise the engineering bar.Communicate clearly and credibly across functions — from individual contributors to senior leadership — adapting your message without losing technical integrity.What We Offer:The opportunity to serve as a technical authority on complex mechanical systems in a high-impact, hands-on engineering role.Direct partnership with hardware engineering, manufacturing, and cross-functional teams to deliver precision-engineered solutions that advance IPA's product capabilities.Autonomy to lead projects from concept through production, with the support of a collaborative engineering organization committed to innovation and excellence.Professional development and career growth within a growing engineering team dedicated to pushing the boundaries of automated dispensing technology.A hybrid work model with flexibility and collaboration built in (4 days in-office, 1 day remote).Competitive compensation, bonus eligibility, and a comprehensive benefits package.A mission-driven culture where your work directly shapes IPA's hardware innovations and supports IPA's purpose: improving infection prevention and operational efficiency in healthcare.