Senior Mechanical Engineer

About the Role

The Senior Mechanical Engineer will serve as the technical lead for plastic component and electro-mechanical assembly design across active projects at both engineering sites. This is a hands-on design leadership role — you'll drive DFM decisions, manage tooling vendors, select materials, and see designs all the way through to validated production parts. You'll also mentor junior engineers and contribute to establishing design standards across the team.

Why This Role Stands Out

• You'll own the full product design lifecycle — from early concept to tooling validation to medium-volume production — and serve as the definitive technical authority on plastic part and electro-mechanical assembly design across two engineering sites.
• Work on real products that ship — 10,000 to 100,000 units per year, across industries including consumer and medical device applications
• Collaborate with a global design team, including support engineers in Taiwan and a worldwide supplier network
• Two-site presence across the Kansas City metro and St. Louis metro areas — variety, visibility, and impact
• Mentor the next generation of engineers and set the bar for CAD standards and DFM best practices
• Join a well-resourced, product-focused company where engineers are respected as core contributors to business outcomes

Key Responsibilities

• Part & Assembly Design: Lead design and development of complex plastic parts, insert-molded components, and assemblies in 3D CAD (SolidWorks preferred; Creo or NX also considered).
• Design for Manufacturing (DFM): Optimize plastic designs for injection molding — draft angles, wall thickness, gating strategies, and tooling approaches suited for medium-volume production.
• Material Selection: Select engineering-grade plastics (PC, ABS, Nylon, Polypropylene, etc.) based on structural, thermal, and chemical performance requirements.
• Simulation & Validation: Perform moldflow analysis, FEA for structural integrity, and tolerance stack-up analysis to ensure fit and function at the assembly level.
• Tooling & Supplier Management: Interface directly with toolmakers and vendors — review mold designs, manage tooling progress, troubleshoot modifications.
• Prototyping & Testing: Lead functional prototyping efforts and coordinate validation testing (ASTM, UL, environmental) to confirm design performance.
• Documentation: Produce and release high-quality 2D drawings with GD&T (ASME Y14.5), Bills of Materials, and engineering specifications.
• Mentorship: Coach and develop junior engineers on plastic design best practices, CAD standards, and DFM principles.

Required Qualifications

• B.S. in Mechanical Engineering, Plastics Engineering, or related field
• 10+ years of hands-on product design experience with a strong focus on plastic injection molded parts
• Expert-level 3D CAD proficiency — SolidWorks preferred; Creo or NX considered
• Deep understanding of injection mold design, moldflow analysis, and tooling processes
• Experience with assembly design techniques: fasteners, snap-fits, adhesive bonding, ultrasonic welding
• Proven track record of launching products in medium-volume production environments (10k–100k units/year)
• Strong FEA and structural analysis skills — using simulation to optimize design, not just validate it
• Ability to travel regularly between the Kansas City metro and St. Louis metro engineering sites

Preferred Qualifications

• Experience with additional plastic processes: blow molding, thermoforming, or extrusion
• Familiarity with materials used in medical device applications, including skin-contact-rated materials
• Exposure to various metal fabrication techniques: machining, casting, extrusion, bending/forming

Benefits

• Competitive salary
• Comprehensive medical, dental, and vision coverage
• 401(k) with company matching
• Company-paid life insurance
• Short- and long-term disability insurance
• Flexible Spending Account (FSA) / Health Savings Account (HSA)
• Generous paid time off
• Employee Assistance Program (EAP)

Pay

$110,000 - $135,000 per year