The Principal Mechanical Engineer is the senior technical leader responsible for driving complex mechanical designs from concept through production. This role blends hands-on engineering, technical leadership, and ownership of new product introduction (NPI). This individual mentors a small team, sets design direction, and solves engineering challenges related to the production launch of new products while remaining deeply involved in modeling, prototyping, testing, and manufacturing readiness.
Responsibilities:
Lead engineering direction, design decisions, and technical strategy for new customer-driven injection molded products. Review customer concepts, CAD models, assemblies, drawings, and technical requirements to advise on design for manufacturing (DFM), tooling approach, cost, and production readiness. Own mechanical development from concept through validation testing (EVT/DVT/PVT) and production launch. Support quoting of tooling and production piece pricing by assessing part complexity, materials, tolerances, cycle time, cavitation, and secondary operations. Mentor and guide a small team of mechanical engineers and designers; review work and elevate design quality. Build and evaluate prototypes using machining, 3D printing, and soft tooling. Partner cross-functionally with engineering, sales, manufacturing, quality, and supply chain teams to ensure seamless integration. Work directly with mold makers, contract manufacturers, and suppliers to optimize part design, tooling design, and mold construction. Perform tooling DFM reviews with suppliers, including gate/runner layout, parting lines, shutoffs, venting, ejection, mold flow, and inspection requirements. Lead tooling launch, sampling, validation, and production release on the manufacturing floor, including ISO 8 cleanroom molding when applicable. Improve design processes, standards, and best practices across the engineering organization. Adhere to federal and state regulations. Adhere to all company policies, processes, and procedures. Perform other duties as requested, directed, or assigned.
Position Qualifications:
Education/Learning Experience:
Bachelor's degree in Mechanical Engineering or related field, or an equivalent degree. Master's degree preferred.
Work Experience:
Minimum of 10 years of mechanical design experience, with at least 5 years in NPD. Experience leading increasingly complex projects or teams.
Skills/Knowledge:
1. Experience in injection-molded part design, tooling considerations, and DFM/DFA through production launch. 2. Strong proficiency in 3D CAD and FEA tools (SolidWorks/SolidWorks Simulation, Creo, NX, or equivalent). 3. Demonstrated ability to lead small engineering teams or project groups. 4. Deep understanding of materials, mechanics, GD&T, and manufacturing processes. 5. Experience launching new production at the factory floor level. 6. Experience working with overseas suppliers. 7. Knowledge of PLM systems, structured documentation practices, and medical device / ISO 8 cleanroom requirements. 1.
