Senior Electro-Mechanical Engineer: Precision Reel-to-Reel

Actalent; Kearny (NJ); Remote; USD 89,000 - 109,000; Full time

Benefits offered by this job

Medical, dental & vision

401(k) Retirement Plan

Remote-friendly environment

Job summary

Actalent is seeking an Electro Mechanical Engineer in Kearny, NJ to design and commission bespoke reel-to-reel process machines that integrate precise mechanical assemblies with advanced control systems.

The role covers roll-to-roll tension control, web handling, winding dynamics, inline inspection technologies, and collaboration with magnet engineers and plasma scientists to push the boundaries of high-value materials manufacturing. Hybrid/remote work is possible for qualified candidates.

Qualifications

• BS, MS, or PhD in Mechatronics, Mechanical Engineering, Electrical Engineering, or a closely related field.
• 8+ years of electromechanical design and commissioning experience on reel-to-reel equipment, preferably with delicate materials.
• Proficiency in electro-mechanical design for high-precision continuous manufacturing systems.
• Experience with tooling design for custom reel-to-reel machinery and process modules.
• Expertise with Beckhoff/TwinCAT 3 and EtherCAT, including structured text programming for motion and process control.
• Experience with tension control and winding algorithms for reel-to-reel processes.
• Expert-level 3D CAD proficiency (NX preferred) for mechanical design.
• Experience using FEA or multibody dynamics to validate designs.

Responsibilities

• Design hardware and controls for bespoke reel-to-reel machines, ensuring tight integration of mechanical and control software.
• Serve as SME for tension control, web handling, winding dynamics, and inline modules.
• Design equipment to handle delicate high-temperature materials with zero-defect tolerance.
• Manage external vendors and integrators, ensuring quality and safety.
• Design and implement advanced inline inspection systems (vision, laser) for process data.
• Identify bottlenecks and implement automated solutions to boost throughput and yield.
• Use 3D CAD and simulations to validate designs under operational conditions.
• Provide guidance to manufacturing and cross-functional teams.

Skills

Mechatronics

Electrical design

Reel-to-reel systems

Beckhoff TwinCAT 3

EtherCAT

NX CAD

FEM / Dynamics

Vendor management

Structured text programming

High-precision manufacturing

Education

Bachelor’s/Master’s/PhD in Mechatronics or related field

Tools

NX

Beckhoff TwinCAT 3

EtherCAT

Simulation tools

Job description

Actalent is seeking an Electro Mechanical Engineer in Kearny, NJ to design and commission bespoke reel-to-reel process machines that integrate precise mechanical assemblies with advanced control systems.

The role covers roll-to-roll tension control, web handling, winding dynamics, inline inspection technologies, and collaboration with magnet engineers and plasma scientists to push the boundaries of high-value materials manufacturing. Hybrid/remote work is possible for qualified candidates.