Senior Mechanical Design Engineer

Job Description

Job Description

Senior Mechanical Product Engineer

About FLX Solutions

FLX Solutions, Inc. builds robotic systems that make inspection and maintenance faster, safer, and more repeatable, especially in tight, hard-to-reach spaces. Our flagship platform, the FLX BOT, is a modular, handheld, snake-like articulating robotic system designed to solve one of the toughest challenges in maintenance: reaching the "last meter" in complex environments. It is already in use with the U.S. Navy, U.S. Air Force, a major DoD prime, and shipbuilders, with expanding applications across industrial, transit, and construction sectors.

We're at the build-and-scale stage. The FLX BOT has moved from prototypes to paying customers in defense, maritime, and industrial markets, and we're growing the team to keep up. If you want your work in the hands of real users within months, not years, and the room to shape how we build, this is the place.

The Opportunity

As Senior Mechanical Product Engineer, you will lead mechanical design efforts, drive innovation, and ensure excellence throughout the entire product development life cycle. FLX Solutions has reached a defining moment. In recent months, we have internalized our product development, transitioning from external design partnerships to an in-house engineering powerhouse. With new Air Force contracts and deepened ties to the Navy and major defense primes, we are executing a strategic shift from pilot programs to full-scale production. Our technology is now moving into high-volume manufacturing across the defense, maritime, industrial, and transportation sectors.

Your impact will extend beyond technical execution; you will play a fundamental role in scaling our organization. By establishing engineering standards, selecting tools, and defining processes, you will mentor future team members and influence our long-term product roadmap. The foundations you build today will define the mechanical engineering excellence at FLX for years to come.

Develop products from concept to production, working closely with our clients and cross-functional teams. As a key member of the team, you will share your experience and knowledge and learn from your colleagues.

Key Responsibilities

• Lead the mechanical design process from concept through production, including system architecture, detailed design, and verification.
• Collaborate with cross-functional teams Electrical Engineering, Software Engineering, and Industrial Design to develop integrated mechanical systems.
• Manage in-house assembly and manufacturing team for assembly of pilot units and advanced prototypes.
• Conduct technical feasibility studies to address complex design challenges.
• Design and build prototypes that meet technical requirements, client needs, and budgets.
• Develop 3D CAD models for complex mechanical systems and ensure designs meet technical, client, and regulatory requirements.
• Perform detailed product design, including the integration of electrical assemblies and complex geometries.
• Write detailed specifications and documentation, and help shape the Quality Management System itself as we build out the processes, templates, and standards that will scale with the team.
• Liaise with customers and suppliers to address project requirements and ensure successful project delivery.
• Document complete designs for manufacture and assembly.

Qualifications

• Bachelor’s degree in mechanical engineering or a related field from a reputable institution.
• 5+ years of experience in mechanical product design and product development, preferably within a multidisciplinary team.
• Proven track record leading the mechanical design of complex systems from concept through production.
• Proficiency in 3D Solidworks software for mechanical and mechatronic system design.
• Experience with both rapid prototyping and traditional manufacturing techniques, including 3D printing, CNC machining, injection molding, and sheet metal design.
• Hands-on experience prototyping and integrating PCBs and electrical assemblies into mechanical systems.
• Excellent problem-solving skills, attention to detail, and ability to lead and work within a team.
• Strong verbal and written communication skills; ability to manage and work effectively with team members, customers, and suppliers.
• Able to mentor and grow the abilities of junior engineers and technicians to complete complex tasks
• Must be a U.S. Citizen.

Preferred Qualifications

• Experience leading mechanical design projects and mentoring technicians and junior engineers.
• Familiarity with Python, ROS (or similar) and C/C++.
• Experience with automation, robotics, or mechatronic system design.
• Experience working in a startup environment or as a member of a small team.
• Ability to leverage modern AI tools to accelerate engineering development

Location

This is an on-site role at our Bethlehem, PA facility, where office, lab, and light-manufacturing are all under one roof. You can move from CAD to the bench, to a contract manufacturer call, without leaving the building. The hands-on nature of the work means in-person presence is the default, with some flexibility for occasional work from home days. Occasional travel (estimated <10%) may be required for customer visits, pilot programs, supplier engagements, and trade events.

Our Fundamental Core Values:

• Do what you say, say what you do.
• We all make mistakes; it is what we do afterwards that defines us.
• Treat all with respect. Period.
• Leave a situation better than you found it.
• Just because something has always been done a certain way, doesn’t mean it has to be done that way in the future.