26-00054J Mechanical Engineer III

Mechanical Engineer III - Industrial Automation & Prototype Development Location: Merrifield, VA (Onsite) Design. Build. Solve. Do you enjoy taking an idea from a sketch to a working prototype? Are you the engineer others rely on when complex equipment needs a practical solution? Join our team supporting the U.S. Postal Service Engineering Headquarters, where you'll help improve one of the largest automated package sorting networks in the country. As a Mechanical Engineer III, you'll design, prototype, troubleshoot, and modernize the equipment that keeps millions of packages moving every day. This is more than a design role-you'll spend time in the engineering lab, machine shop, and field turning concepts into real-world solutions. What You'll Do As part of the Package Sorting Technology Group, you'll: Design, fabricate, machine, weld, and assemble mechanical and electrical prototypes Create custom fixtures, tooling, brackets, carts, test equipment, and ergonomic workstations Design mechanical components and assemblies using 3D CAD software Evaluate and replace obsolete (End-of-Life) components used in automated package sorting equipment Engineer retrofit solutions that improve equipment reliability, safety, and performance Troubleshoot mechanical, pneumatic, electrical, and automation issues affecting production systems Perform root cause analysis to eliminate recurring equipment failures and operational bottlenecks Design custom tools and semi-automated equipment that improve productivity and reduce operator fatigue Participate in engineering design reviews and collaborate with project managers, suppliers, maintenance teams, and safety personnel Conduct field inspections and develop Modification Work Orders (MWOs) for equipment upgrades deployed nationwide What We're Looking For Required Qualifications Bachelor's degree in Mechanical Engineering or a related engineering discipline 4+ years of mechanical engineering experience Experience supporting industrial automation, material handling systems, manufacturing equipment, or conveyor systems Hands-on experience with prototype fabrication, machining, welding, and mechanical assembly Proficiency with 3D CAD modeling and engineering drawings Experience interpreting fabrication prints and GD&T Knowledge of pneumatic systems and industrial mechanical equipment Strong troubleshooting, analytical, and root cause analysis skills Experience creating technical documentation, retrofit instructions, or engineering procedures Preferred Qualifications Experience with package, parcel, mail, or logistics automation systems Experience designing industrial grounding or static mitigation systems Knowledge of industrial electrical circuits, E-stop systems, or LED indicator controls Experience documenting engineering projects using drone photography or video Familiarity working with OSHA, safety, or facility engineering teams Why Join Our Team? You'll work on engineering projects that have a direct impact on the nation's postal infrastructure. Your ideas won't stay on paper-you'll design, build, test, and deploy solutions used in USPS facilities across the country. What We Offer Competitive Salary Medical, Dental & Vision Insurance 401(k) Retirement Plan Life Insurance Short-Term & Long-Term Disability Paid Vacation, Sick Leave & Company Holidays Paid Parental Leave Professional Development & Training Opportunity to work on large-scale industrial automation projects Additional Information Location: Merrifield, VA Schedule: Monday-Friday, 8:00 AM-5:00 PM Travel: Less than 10% Occasional evening or weekend support may be required Must successfully pass a pre-employment background check and drug screening. Ready to build solutions that keep America moving? Apply today and become part of a team that's engineering the future of package automation. Employment Type: Full Time Salary: $75,000 - $80,000 Annual