Mechanical Design and Prototyping Engineer

FLX Solutions, Inc.; Bethlehem (Northampton County); Hybrid; USD 80,000 - 110,000; Full time

Job summary

FLX Solutions, Inc. is seeking a Mechanical Design & Prototyping Engineer to work hands-on in the lab, building and testing hardware alongside our Assembly team. You will design jigs and fixtures, apply GD&T, and generate manufacturing drawings to keep builds accurate and repeatable.

This ground-floor role sits as the FLX BOT platform scales from pilot programs to production. You’ll start with hands-on build, test, and lab work, then grow into more design responsibilities with mentorship from

Qualifications

• Bachelor's degree in mechanical engineering from ABET-accredited school.
• 3+ years of hands-on mechanical design, prototyping or related engineering role.
• Proficiency in 3D CAD (SolidWorks preferred).
• Practical experience with 3D printing and rapid prototyping.
• Working knowledge of GD&T and ability to generate manufacturing drawings.
• Experience building and troubleshooting physical prototypes from drawings/BOMs.
• Organized approach to documentation and parts/inventory tracking.
• Must be a U.S. Citizen.

Responsibilities

• Assist with running the engineering lab and equipment readiness.
• Manage lab and build-area parts inventory.
• Refine the manufacturing process and workflows.
• Execute 3D printing for prototypes and production aids.
• Build and assemble prototypes from drawings and BOMs.
• Perform CAD work designing jigs, fixtures, and tooling.
• Implement test processes, run tests, and report results.
• Apply GD&T and generate manufacturing drawings.
• Document designs and builds to support manufacture and assembly.
• Collaborate with Electrical and Assembly teams to keep builds moving.

Education

Bachelor's degree in mechanical engineering (ABET-accredited)

Tools

SolidWorks

Job description

We're Always Looking for Amazing People.

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

The Mechanical Design & Prototyping Engineer role sits at the intersection of technician and engineer, with a clear path to grow into a full design engineering role. You'll be hands-on in the lab every day, building and testing hardware alongside our Assembly team, keeping the 3D printers running, and managing parts inventory, while also doing real engineering work: designing jigs and fixtures in CAD, applying GD&T (Geometric Dimensioning & Tolerancing) and generating the drawings that keep our builds accurate and repeatable.

This is a ground-floor seat on the FLX BOT platform as it moves from pilot programs into full-scale production. You'll work closely with the Electrical and Assembly teams and the Senior Mechanical Design Engineer, You'll start with the hands-on build, test, and lab work and take on more of the design as you build your track record, with a clear path toward a senior design role.

Key Responsibilities:

• Assist with running the engineering lab, including day-to-day upkeep and equipment readiness
• Manage parts inventory for the lab and build area
• Contribute to and help refine the manufacturing process
• Execute and manage 3D printing for prototypes and production aids
• Build and assemble prototypes from drawings and BOMs
• Perform CAD work such as designing jigs, fixtures, and tooling
• Implement test processes — running tests, collecting data, and reporting results
• Apply GD&T (Geometric Dimensioning & Tolerancing) and generate manufacturing drawings
• Document designs and builds to support manufacture and assembly
• Collaborate with the Electrical and Assembly teams to keep builds moving

Qualifications:

Required:

• Bachelor's degree in mechanical engineering or a related field from an ABET-accredited institution
• 3+ years of experience in mechanical design, prototyping, or a related hands-on engineering/technician role
• Working proficiency in 3D CAD (SolidWorks preferred)
• Practical experience with 3D printing and rapid prototyping equipment
• Working knowledge of GD&T and the ability to generate clear manufacturing drawings
• Comfortable building and troubleshooting physical prototypes from drawings or BOMs
• Organized approach to documentation and parts/inventory tracking
• Must be a U.S. Citizen

Preferred:

• Experience working in a startup or small-team environment
• Experience supporting test processes such as running tests, collecting and reporting data
• Experience with project management tools like ClickUp
• Exposure to electrical/PCB integration into mechanical assemblies
• Exposure to embedded software or scripting (Python, C/C++) for test, data collection, or automation
• Ability to leverage modern AI tools to accelerate engineering development

Mechanical Design and Prototyping Engineer