Mechanical Engineer

Job Description:

Mechanical Engineer The Mechanical Engineer will lead complex mechanical design engagements from initial concept through the start of mass production, working closely with internal and external stakeholders. This role focuses on developing, testing, and validating robust mechanical designs for battery pack enclosures, charging ports and docks, and related interfaces, while balancing performance, cost, manufacturability, and industrial design. The engineer will drive continuous improvement, mentor less experienced engineers, and help foster a culture of learning, openness, and accountability. Responsibilities Lead mechanical engagements with internal and external customers to define requirements and translate them into clear specifications. Collaborate cross-functionally with project management, manufacturing, procurement, quality, system, and test engineering teams throughout the product development lifecycle. Develop, test, and validate robust mechanical designs that meet performance, reliability, and regulatory requirements. Incorporate creative industrial design concepts and features while ensuring designs meet all technical specifications and constraints. Lead mechanical component selection and optimization for battery pack enclosures, charging ports and docks, and related mechanical interfaces. Apply design integrity best practices for ultrasonic and laser welding, snap fits, screws, thermal management, and other joining and assembly methods. Work with system, manufacturing, and test engineers to generate FMEA (Failure Modes and Effects Analysis) and DFM (Design for Manufacturability) reports. Identify and mitigate risks to minimize mass production issues and control production costs. Lead and support the bring-up and debugging of new mechanical prototypes, including implementing necessary modifications to components and interfaces. Provide clear reports on product performance and conformity to customer requirements and applicable standards. Lead and support engineering verification testing, including drop, vibration, shock, ingress protection, and thermal tests, and drive design changes required to achieve compliance. Explore and evaluate new and existing materials and manufacturing methods to solve complex design challenges. Provide sustaining engineering support for existing products, including performing root cause analysis and implementing corrective actions for field issues. Lead, train, and guide less experienced engineers, sharing best practices and technical expertise. Help establish and reinforce a culture of learning, openness, and accountability within the engineering team. Essential Skills BS, MS, or PhD in Mechanical Engineering. Minimum 10 years of experience with new product introductions from concept through the start of mass production in consumer, telecom, medical, automotive, and/or military industries. 8+ years of experience with MCAD tools such as SolidWorks or CREO, with a strong preference for SolidWorks. Proficiency in SolidWorks and mechanical engineering design principles. Strong experience in new product development, including requirements definition, design, validation, and transfer to manufacturing. Strong quantitative, analytical, and problem-solving skills applied to mechanical design challenges. Experience performing structural and thermal FEA (Finite Element Analysis). Proficiency in GD&T (Geometric Dimensioning and Tolerancing). Experience with injection molding processes for plastic components. Experience with metal stamping and forming processes. Strong verbal and written communication skills in English. Strong knowledge and regular use of Microsoft Office products. Additional Skills & Qualifications Familiarity with ISO standards relevant to mechanical design and product development. Experience generating FMEA and DFM reports in collaboration with cross-functional teams. Experience in designing for ultrasonic and laser welding, snap fits, screws, and thermal management solutions. Experience supporting engineering verification testing for drop, vibration, shock, ingress protection, and thermal performance. Experience providing sustaining engineering support and performing root cause analysis for field issues. Demonstrated ability to mentor and guide less experienced engineers and contribute to a collaborative team culture. Job Type & Location This is a Permanent position based out of Darien, IL. Pay and Benefits The pay range for this position is $100000.00 - $125000.00/yr. pto, health dental vision Workplace Type This is a fully onsite position in Darien,IL. Application Deadline This position is anticipated to close on May 29, 2026. About Actalent Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law. If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

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Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

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It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability. Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.