Mechanical Design & Prototyping Engineer

FLX Solutions, Inc.; Bethlehem (Northampton County); On-site; USD 75,000 - 105,000; Full time

Job summary

FLX Solutions, Inc. seeks a Mechanical Design & Prototyping Engineer to join our hands-on lab environment, building and testing hardware alongside the Assembly team. You’ll keep 3D printers running, manage parts inventory, and contribute to jigs and fixtures in CAD, applying GD&T to generate manufacturing drawings.

You’ll grow from hands-on build/test work toward a more design-focused role, collaborating with Electrical and Senior Mechanical Design teams as production scales.

Qualifications

• Bachelor's degree in mechanical engineering from ABET-accredited institution.
• 3+ years in mechanical design, prototyping, or hands-on engineering/tech role.
• SolidWorks or 3D CAD proficiency.
• Experience with 3D printing and rapid prototyping equipment.
• Knowledge of GD&T and ability to generate clear manufacturing drawings.
• U.S. Citizen.
• Ability to document designs and manage parts inventory.

Responsibilities

• Run and maintain the engineering lab equipment.
• Manage lab and build-area parts inventory.
• Refine manufacturing processes.
• Execute 3D printing for prototypes and production aids.
• Build prototypes from drawings and BOMs.
• Design jigs, fixtures, and tooling in CAD.
• Apply GD&T and generate manufacturing drawings.
• Document designs and builds for manufacturing.
• Collaborate with Electrical and Assembly teams to move builds.

Skills

3D CAD (SolidWorks)

3D Printing

GD&T

Prototype testing

Documentation/inventory

Education

ABET-accredited Mechanical Engineering degree

Tools

ClickUp

Job description

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.

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 best practices, 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