Mechanical Design Engineer

Senior Mechanical Test Development Engineer

Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world. A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment. If you are excited about a role but don't meet every bullet point, we encourage you to apply and join us to create the extraordinary.

To support our extraordinary teams who build innovative products and contribute to our growth, we are seeking a Senior Mechanical Test Development Engineer located in Austin, Texas.

Reporting to the Test Development Manager, the Senior Mechanical Test Development Engineer is responsible for designing, developing, and supporting mechanical solutions used in manufacturing test environments. This role focuses on the development of Automated Test Equipment (ATE), test fixtures, electromechanical mechanisms, and associated manufacturing test solutions used for Printed Circuit Board Assemblies (PCBAs) and High-Level Assemblies (HLAs).

The engineer will work closely with electrical, software, manufacturing, quality, and customer engineering teams to develop reliable, cost-effective, and scalable test solutions while supporting product introduction, production ramp, and ongoing manufacturing operations.

Required Qualifications

• Bachelor's degree in mechanical engineering or related engineering discipline.
• Minimum 5 years of experience in mechanical design, test development, manufacturing engineering, or related engineering disciplines.
• Demonstrated experience designing electromechanical fixtures and mechanical test mechanisms.
• Experience developing manufacturing test fixtures for PCBAs and/or high-level assemblies.
• Experience supporting automated test equipment (ATE) development and deployment.
• Experience working with fabrication suppliers, machine shops, and manufacturing teams.
• Experience with Pneumatic Fixture Design
• Experience with Bed-of-Nails Fixtures

Key Responsibilities

Mechanical Test Fixture Development

• Design and develop turnkey mechanical solutions for automated manufacturing test systems, including manual, semi-automated, and fully automated test equipment.
• Design electromechanical fixtures, mechanisms, and tooling used for functional testing of PCBAs and high-level assemblies.
• Develop robust mechanical interfaces that support reliable electrical connection, product alignment, and repeatable testing throughout the product lifecycle.
• Design fixture structures utilizing pneumatic, vacuum, spring-loaded, and other motion-control techniques as required.
• Support fixture standardization and modular design initiatives to improve development efficiency and long-term maintainability.

Mechanical Design & Documentation

• Create complete 3D CAD models, assembly drawings, detail drawings, and engineering documentation using SolidWorks and related CAD tools.
• Generate and maintain Bills of Material (BOMs), Engineering Change Orders (ECOs), and associated documentation packages.
• Perform tolerance stack-up analysis, Design for Manufacturability (DFM), and Design for Assembly (DFA) reviews.
• Develop documentation sufficient for fabrication, assembly, maintenance, and field support activities.
• Ensure compliance with internal engineering standards and customer requirements.

Prototype Development & Validation

• Build, assemble, and validate prototype fixtures and mechanical subsystems.
• Conduct engineering evaluations, verification testing, and design validation activities.
• Analyze test results, identify root causes of failures, and implement corrective actions.
• Support reliability improvements through iterative design enhancement and validation testing.
• Document testing methodologies, results, lessons learned, and recommended design improvements.

Manufacturing & Supplier Support

• Interface with machine shops, fabrication vendors, and component suppliers to support fixture production.
• Review manufacturing processes and recommend improvements to reduce cost and improve quality.
• Support CNC machining operations and fabrication activities associated with fixture development.
• Utilize rapid prototyping and additive manufacturing technologies, including 3D printing, to accelerate development cycles.
• Support fixture builds from prototype through production deployment.

Cross-Functional Collaboration

• Partner with Electrical, Software, Manufacturing, Quality, and Product Engineering teams to establish effective test strategies.
• Collaborate with test development engineers to integrate mechanical, electrical, and software elements into complete test systems.
• Interface directly with customers to clarify requirements, address technical issues, and communicate project status.
• Provide technical guidance and mentorship to technicians and junior engineers.
• Participate in project planning, risk assessment, scheduling, and cost estimation activities.

Continuous Improvement & Innovation

• Research emerging fixture technologies, manufacturing processes, and automated testing methodologies.
• Drive improvements in fixture reliability, throughput, ergonomics, serviceability, and overall cost of ownership.
• Identify opportunities for standardization and reuse across manufacturing test platforms.
• Stay current with industry trends, materials, and mechanical design best practices.

Technical Skills

• Proficiency with SolidWorks for 3D modeling and detailed mechanical design.
• Strong understanding of mechanical design principles, GD&T, and Tolerance Stack-Up analysis.
• Experience preparing engineering drawings, BOMs, and ECO documentation.
• Knowledge of manufacturing processes including machining, sheet metal fabrication, plastics, and assembly methods.
• Experience with CNC machining setup and operation.
• Proficiency with Microsoft Office applications.
• Basic understanding of Automation Integration for Inline ATE fixturing

Preferred Qualifications

• Research emerging fixture technologies, manufacturing processes, and automated testing methodologies.
• Drive improvements in fixture reliability, throughput, ergonomics, serviceability, and overall cost of ownership.
• Identify opportunities for standardization and reuse across manufacturing test platforms.
• Stay current with industry trends, materials, and mechanical design best practices.

Key Competencies

Technical

• Mechanical Fixture Design
• Automated Test Equipment (ATE)
• Electromechanical Systems
• Design for Manufacturing (DFM)
• Design for Testability (DFT)
• Tolerance Stack-Up Analysis
• Root Cause Analysis
• Prototype Development
• CNC Machining
• Additive Manufacturing / 3D Printing

Professional

• Technical Leadership
• Project Management
• Customer Communication
• Supplier Management
• Problem Solving
• Cross-Functional Collaboration
• Continuous Improvement
• Mentoring and Coaching

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What you'll receive for the great work you provide:

• Full range of medical, dental, and vision plans
• Life Insurance
• Short-term and Long-term Disability
• Matching 401(k) Contributions
• Vacation and Paid Sick Time
• Tuition Reimbursement

Job Category: Production Engineering

Is Sponsorship Available?

No. Flex is an Equal Opportunity Employer and employment selection decisions are based on merit, qualifications, and abilities. We do not discriminate based on: age, race, religion, color, sex, national origin, marital status, sexual orientation, gender identity, veteran status, disability, pregnancy status, or any other status protected by law. We're happy to provide reasonable accommodations to those with a disability for assistance in the application process. Please email View email address on click.appcast.io and we'll discuss your specific situation and next steps (NOTE: this email does not accept or consider resumes or applications. This is only for disability assistance. To be considered for a position at Flex, you must complete the application process first).