Principal Mechanical Engineer

Nelson Miller Group; Northern (KY); Hybrid; USD 140,000 - 155,000; Full time

Benefits offered by this job

Medical, dental and vision coverage

401(k) Retirement Savings Plan

Paid holidays

Sick leave

Vacation time

Employee assistance program

Job summary

Nelson Miller Group in Kentucky is seeking a Principal Mechanical Engineer to drive complex mechanical designs from concept to production. You will mentor a small team, own NPI, and manage EVT/DVT/PVT, prototyping, and manufacturing readiness.

You will collaborate with mold makers, contract manufacturers and suppliers to optimize design and tooling. This role requires hands-on leadership, CAD/FEA expertise, and a strong focus on DFM through production launch.

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field; Master’s preferred.
• Minimum of 10 years mechanical design experience, with at least 5 years in NPD; leadership experience.
• Experience in injection-molded part design, tooling considerations, and DFM/ DFA through production launch.
• Strong proficiency in 3D CAD and FEA tools (SolidWorks/SolidWorks Simulation, Creo, NX, or equivalent).
• Demonstrated ability to lead small engineering teams or project groups.
• Deep understanding of materials, mechanics, GD&T, and manufacturing processes.
• Experience launching new production at the factory floor level.
• Experience working with overseas suppliers.
• Knowledge of PLM systems, structured documentation practices, and medical device / ISO 8 cleanroom requirements.
• Travel: Ability to travel approximately 10%.

Responsibilities

• Lead engineering direction, design decisions, and technical strategy for new customer-driven injection molded products.
• Review customer concepts, CAD models, assemblies, drawings, and technical requirements to advise on DFM, tooling approach, cost, and production readiness.
• Own mechanical development from concept through validation testing (EVT/DVT/PVT) and production launch.
• Support quoting of tooling and production piece pricing by assessing part complexity, materials, tolerances, cycle time, cavitation, and secondary operations.
• Mentor and guide a small team of mechanical engineers and designers; review work and elevate design quality.
• Build and evaluate prototypes using machining, 3D printing, and soft tooling.
• Partner cross-functionally with engineering, sales, manufacturing, quality, and supply chain teams to ensure seamless integration.
• Work directly with mold makers, contract manufacturers, and suppliers to optimize part design, tooling design, and mold construction.
• Perform tooling DFM reviews with suppliers, including gate/runner layout, parting lines, shutoffs, venting, ejection, mold flow, and inspection requirements.
• Lead tooling launch, sampling, validation, and production release on the manufacturing floor, including ISO 8 cleanroom molding when applicable.
• Improve design processes, standards, and best practices across the engineering organization.
• Adhere to federal and state regulations.
• Adhere to all company policies, processes, and procedures.
• Perform other duties as requested, directed, or assigned.

Skills

Team leadership

DFM/ DFA

NPD experience

Materials & mechanics

GD&T proficiency

Production launch

Overseas suppliers

Education

Bachelor's in Mechanical Engineering

Master's degree preferred

Tools

SolidWorks

SolidWorks Simulation

Creo

NX

PLM systems

Job description

Description

Overview

Since 1904, Nelson Miller Group (NMG) has been a leading global provider of custom engineering and manufacturing solutions across industrial, IoT, lighting, medical, telecommunications, consumer, and aerospace & defense sectors.

We bring ideas to life through global Joint Design Manufacturing—helping customers innovate, grow, and deliver products the world can depend on.

At the heart of our culture is The Nelson Miller Group Way: Unleash the Power of One — One Global Team / One Vision / One Commitment.

Our century-long legacy is built on a deep commitment to innovation, operational excellence, and unwavering customer satisfaction—principles strengthened by our TEAM core values: Take Ownership, Exceed Expectations, Act with Integrity, and Make an Impact.

Job Summary

The Principal Mechanical Engineer is the senior technical leader responsible for driving complex mechanical designs from concept through production. This role blends hands-on engineering, technical leadership, and ownership of new product introduction (NPI). This individual mentors a small team, sets design direction, and solves engineering challenges related to the production launch of new products while remaining deeply involved in modeling, prototyping, testing, and manufacturing readiness.

Responsibilities

• Lead engineering direction, design decisions, and technical strategy for new customer-driven injection molded products.
• Review customer concepts, CAD models, assemblies, drawings, and technical requirements to advise on design for manufacturing (DFM), tooling approach, cost, and production readiness.
• Own mechanical development from concept through validation testing (EVT/DVT/PVT) and production launch.
• Support quoting of tooling and production piece pricing by assessing part complexity, materials, tolerances, cycle time, cavitation, and secondary operations.
• Mentor and guide a small team of mechanical engineers and designers; review work and elevate design quality.
• Build and evaluate prototypes using machining, 3D printing, and soft tooling.
• Partner cross-functionally with engineering, sales, manufacturing, quality, and supply chain teams to ensure seamless integration.
• Work directly with mold makers, contract manufacturers, and suppliers to optimize part design, tooling design, and mold construction.
• Perform tooling DFM reviews with suppliers, including gate/runner layout, parting lines, shutoffs, venting, ejection, mold flow, and inspection requirements.
• Lead tooling launch, sampling, validation, and production release on the manufacturing floor, including ISO 8 cleanroom molding when applicable.
• Improve design processes, standards, and best practices across the engineering organization.
• Adhere to federal and state regulations.
• Adhere to all company policies, processes, and procedures.
• Perform other duties as requested, directed, or assigned.

Requirements

Position Qualifications

• Education/Learning Experience: Bachelor’s degree in Mechanical Engineering or related field, or an equivalent degree. Master’s degree preferred.
• Work Experience: Minimum of 10 years of mechanical design experience, with at least 5 years in NPD. Experience leading increasingly complex projects or teams.
• Skills/Knowledge:
• Experience in injection-molded part design, tooling considerations, and DFM/DFA through production launch.
• Strong proficiency in 3D CAD and FEA tools (SolidWorks/SolidWorks Simulation, Creo, NX, or equivalent).
• Demonstrated ability to lead small engineering teams or project groups.
• Deep understanding of materials, mechanics, GD&T, and manufacturing processes.
• Experience launching new production at the factory floor level.
• Experience working with overseas suppliers.
• Knowledge of PLM systems, structured documentation practices, and medical device / ISO 8 cleanroom requirements.
• Travel: Ability to travel approximately 10%.
• Behavioral Competencies: Safety Leadership & Culture | Team Leadership & Development – People Leaders | Customer Focus | Strategic Alignment & Business Acumen | Communication, Influence & Change Management | Accountability & Performance Management– People Leaders | Decision Making & Problem Solving | Knowledge, Professional & Technical Skills

Physical Requirements / Working Conditions

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions.

Due to ITAR and / or CUI compliance, this position requires candidates to be a U.S. Citizen, Permanent Resident Alien, or Protected Individual per 8 U.S.C.1324b(a)(3).

Candidates being considered for hire must pass a pre-employment background check.

Compensation and Benefits

Pay Range: $140k - $155k (Pay to be determined by the experience, knowledge, skills, and abilities of the candidate, and alignment with market data)

Benefits Offered: Comprehensive benefit package including medical, dental and vision coverage; company-paid basic life/AD&D insurance, short-term and long-term disability insurance; voluntary supplemental insurances, flexible spending accounts and employee assistance program (EAP). Sick Leave, Vacation Time, and company-paid Holidays are also provided as paid time off. Nelson Miller Group also provides a 401(k) Retirement Savings Plan option with a safe harbor non-elective company contribution.

Nelson Miller Group is an Equal Opportunity/Affirmative Action employer.? All qualified applicants will receive consideration for employment without regard to race, color, religion, sex including sexual orientation and gender identity, national origin, disability, protected Veteran status, or any other characteristic protected by applicable federal, state, or local law.