Senior Mechanical Design Engineer

FLX Solutions, Inc.; Bethlehem (Northampton County); On-site; USD 120,000 - 160,000; Full time

Job summary

FLX Solutions, Inc. in Bethlehem, PA seeks a Senior Mechanical Design Engineer to lead mechanical design from concept to production, drive innovation, and set engineering standards as the team scales from GTM design to high-volume production for defense, maritime, and industrial markets.

You will mentor engineers, manage the lab and build processes, own CAD development, and coordinate with Electrical and Software teams to ensure designs meet client needs, regulatory requirements, and project

Qualifications

• ABET-accredited B.S. in Mechanical Engineering or related field.
• 7+ years in mechanical product design and development.
• Proven track record leading complex mechanical systems from concept to production.
• Experience managing or leading engineering/assembly teams.
• Proficiency in SolidWorks for mechanical/mechatronic systems.
• Experience with rapid prototyping and traditional manufacturing (3D printing, CNC, injection molding, sheet metal).
• Hands-on prototyping and integrating PCBs/electrical assemblies into mechanicals.
• Ability to own GD&T on drawings and apply fundamentals judiciously.
• Excellent problem-solving, attention to detail, and teamwork.

Responsibilities

• Lead the mechanical design process from concept through production, including architecture, design, testing, and verification.
• Coordinate with Electrical, Software, and Industrial Design to deliver integrated mechanical systems.
• Oversee manufacturing process development as the company scales to full production.
• Deliver prototype and pilot builds, track status, resolve issues, ensure requirements and budgets.
• Produce 3D CAD models for complex mechanical systems and integrate electrical assemblies.
• Perform tolerancing, fits, and engineering analysis to ensure manufacturability and design integrity.

Skills

CAD leadership

GD&T

Tolerancing

Mentoring

Verbal communication

Team leadership

Problem-solving

Project coordination

Education

Bachelor's degree in Mechanical Engineering

Tools

SolidWorks

3D CAD modeling

Python

C/C++

ROS

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

As Senior Mechanical Design Engineer, you will lead mechanical design efforts, drive innovation, and ensure excellence throughout the entire product development life cycle. With new Air Force contracts and deepened ties to the Navy and major defense primes, we are executing a strategic shift from pilot programs to go-to-market (GTM) design and then full-scale production. Our technology is now moving into high-volume manufacturing across the defense, maritime, industrial, and transportation sectors.

Your impact goes beyond technical execution. You'll set the engineering standards, tools, and processes the team scales on, own the lab and the build process, mentor the engineers who follow you, and shape the product roadmap as we move into final GTM efforts and full-scale production.

Key Responsibilities

• Lead the mechanical design process from concept through production, including system architecture, design, feasibility studies, testing, and verification.
• Lead design reviews, working closely with Electrical Engineering, Software Engineering, and Industrial Design to develop integrated mechanical systems.
• Oversee the manufacturing process and lead its ongoing development as FLX scales from pilot programs into full-scale production.
• Own delivery of prototype and pilot-unit builds, tracking status, resolving issues, and ensuring each one meets technical requirements, client needs, and budget.
• Take ownership of the most complex, high-level CAD and system-level engineering work, developing 3D CAD models for complex mechanical systems and performing detailed product design, including the integration of electrical assemblies and complex geometries, to ensure designs meet technical, client, and regulatory requirements.
• Perform tolerancing, fits, and engineering analysis to ensure design integrity and manufacturability.

Qualifications

Required:

• Bachelor's degree in mechanical engineering or a related field from an ABET-accredited institution
• 7+ years of experience in mechanical product design and product development, preferably within a multidisciplinary team
• Proven track record leading the mechanical design of complex systems from concept through production
• Experience managing or leading engineering and/or assembly teams
• Proficiency in SolidWorks for mechanical and mechatronic system design
• Experience with both rapid prototyping and traditional manufacturing techniques, including 3D printing, CNC machining, injection molding, and sheet metal design
• Hands-on experience prototyping and integrating PCBs and electrical assemblies into mechanical systems
• Proficiency in tolerancing and engineering analysis for fit and function
• Able to own GD&T on our drawings with a strong working knowledge of the fundamentals and the judgment to know when and where to apply them
• Excellent problem-solving skills, attention to detail, and ability to lead and work within a team
• Strong verbal and written communication skills; ability to manage and work effectively with team members, customers, and suppliers
• Able to mentor and grow the abilities of junior engineers and technicians to complete complex tasks
• Must be a U.S. Citizen

Preferred:

• Experience working in a startup environment or as a member of a small team
• Experience with project management tools like ClickUp
• Familiarity with Python, C/C++, and embedded systems
• Experience with robotics (ROS), sensor systems, automation, or mechatronic system design
• Ability to leverage modern AI tools to accelerate engineering development