Mechanical Designer - Automation & Integration

Applied Controls, Inc.; Exton (PA); On-site; USD 70,000 - 100,000; Full time

Job summary

Applied Controls, Inc., a SunSource company, in Exton, PA, seeks a Mechanical Designer to join the Integration team. You will transform customer requirements into fully engineered automation solutions, including layouts, tooling, fixtures, and fabrication-ready documentation.

You will collaborate with engineering, controls, and project teams from concept through installation, ensuring design quality, manufacturability, and clear documentation for successful handoff and field deployment.

Qualifications

• 3–5 years of mechanical design experience in automation or manufacturing environments.
• Experience taking designs from concept through fabrication, assembly, and installation.
• Experience designing tooling, fixtures, or custom mechanical systems.
• Associate’s or Bachelor’s degree in Mechanical Engineering or equivalent experience.

Responsibilities

• Develop 3D models and fabrication drawings for automation systems, tooling, fixtures, guarding, and structural assemblies using CAD software (e.g., SolidWorks).
• Design components and assemblies with manufacturability, cost, and durability in mind (sheet metal, machined parts, welded structures).
• Create and maintain BOMs to support sourcing and procurement.
• Apply GD&T principles to ensure designs are manufacturable, inspectable, and repeatable.
• Develop full system and cell layouts, tooling interfaces, mounting schemes, and changeover strategies.

Skills

CAD modeling

SolidWorks

GD&T

Sheet metal

Welding

Documentation

Team collaboration

Education

Associate’s or Bachelor’s degree in Mechanical Engineering

Tools

SolidWorks

AutoCAD

Job description

Applied Controls, a SunSource company, is a high-tech automation distributor and solutions provider. We educate and support local manufacturers in implementing emerging technologies to reduce costs, increase productivity and improve safety. Our offerings range from industrial computers and software, Robotics, Machine Vision, and Motion Control. Our goal is to increase productivity to keep manufacturing in America successful and prosperous. www.appliedc.com

As a Mechanical Designer within the Integration team, you will serve as a key contributor to the design and development of custom automation systems. You will transform customer requirements, application details, and site conditions into fully engineered solutions, including system layouts, tooling, fixturing, and fabrication-ready documentation.

You will collaborate closely with engineering, controls, and project teams from concept through installation and final handoff. This role requires a strong focus on design quality, manufacturability, and clear documentation, along with the ability to communicate effectively with both internal teams and customers.

Responsibilities

• Develop 3D models and detailed fabrication drawings for automation systems, tooling, fixtures, guarding, and structural assemblies using CAD software (e.g., SolidWorks)
• Design components and assemblies with consideration for manufacturability, cost, and durability (sheet metal, machined parts, welded structures, etc.)
• Create and maintain bills of materials (BOMs) to support sourcing and procurement
• Apply GD&T principles to ensure designs are manufacturable, inspectable, and repeatable
• Perform engineering analysis (e.g., FEA or hand calculations) to validate structural integrity and safety factors where applicable

System Layout & Integration Design

• Develop full system and cell layouts, accounting for equipment footprint, operator interaction, maintenance access, and safety requirements
• Define and document tooling interfaces, mounting schemes, and changeover strategies
• Collaborate with controls and electrical teams on routing for cables, pneumatics, sensors, and I/O components
• Design for efficient assembly and installation, identifying opportunities to simplify field deployment

Customer & Project Support

• Present design concepts, layouts, and models to internal stakeholders and customer teams for review and alignment
• Incorporate customer feedback, site constraints, and application requirements into design revisions
• Account for real-world conditions such as facility layout, floor loading, clearances, and existing equipment interfaces
• Support project handoff by delivering accurate and complete documentation packages (drawings, BOMs, manuals, and as-built updates)

Standards & Continuous Improvement

• Contribute to the development and maintenance of reusable design standards, components, and libraries
• Follow and help improve internal design practices, templates, revision control, and file management processes
• Identify recurring design challenges and help implement standardized solutions to improve efficiency and consistency
• Support continuous improvement initiatives within the engineering and integration teams

Requirements

• 3–5 years of mechanical design experience in automation, equipment design, or custom manufacturing environments
• Proven experience taking designs from concept through fabrication, assembly, and installation
• Experience designing tooling, fixtures, or custom mechanical systems
• Experience working in regulated or high-compliance industries prefered
• Associate’s or Bachelor’s degree in Mechanical Engineering, Mechanical Design, or equivalent experience prefered

Technical Skills

• Strong proficiency in CAD software (SolidWorks preferred; AutoCAD or equivalent is a plus)
• Solid understanding of GD&T and creation of production-ready drawing packages
• Experience with common manufacturing processes: sheet metal, machining, welding, and additive manufacturing
• Familiarity with system layout considerations including access, safety, and maintainability
• Experience selecting and integrating off-the-shelf components (actuators, linear systems, sensors, etc.)
• Working knowledge of cable management, pneumatic routing, and general system integration practices
• Strong attention to detail and commitment to high-quality deliverables
• Collaborative and team-oriented with clear communication skills
• Ability to manage multiple projects and priorities effectively
• Practical, solutions-oriented mindset with a focus on execution
• CAD certification (e.g., SolidWorks)
• Experience with simulation or layout validation tools
• Background in automation applications such as assembly, material handling, machine tending, or inspection systems
• Familiarity with applicable safety standards (ANSI, ISO, OSHA, etc.)

Equal Opportunity Employer, including disability and protected veteran status. If you are an individual with a disability and require an accommodation to complete the application process, please contact [e-mail] to request reasonable accommodation. Only requests for accommodation in the application process will be returned from this email address. This employer uses E-Verify. Please click here for additional information. (For Illinois E-Verify information click here, aquí). Sun-Source | Privacy Policy #appliedcontrolsassc

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.