Senior Mechanical Design Engineer

Brightpath Associates LLC; Goodfield (IL); On-site; USD 90,000 - 130,000; Full time

Job summary

Brightpath Associates LLC in Illinois seeks a Senior Mechanical Design Engineer to drive end-to-end product development, mentor engineers, and lead complex design initiatives from napkin sketch to manufacturing. This is a senior individual contributor role emphasizing technical depth and project accountability.

You will collaborate with suppliers and manufacturers, lead DFM initiatives, and guide cross-functional teams to ensure robust, manufacturable designs and timely product launches.

Qualifications

• Bachelor's degree in Mechanical Engineering or related discipline.
• 7+ years of hands-on mechanical/product design experience launching commercial products.
• Ability to manage multi-stakeholder design projects without direct supervisory authority.
• Strong hands-on experience with prototyping, testing, and DFM.

Responsibilities

• Lead cross-functional teams through full development lifecycles with schedules and deliverables.
• Mentor junior engineers on design, manufacturability, and failure analysis.
• Drive mechanical architecture, CAD modeling, component selection, and drawing release.
• Collaborate with suppliers and manufacturing partners for high-yield production.
• Support IP strategy and prototype validation prior to tooling.

Skills

Mechanical design

Cross-functional leadership

3D CAD modeling

DFM principles

Education

Bachelor's degree in Mechanical Engineering

Tools

3D CAD software

Job description

We are looking for a Senior Mechanical Design Engineer to drive end-to-end product development, elevate our technical capabilities, and mentor the next generation of engineers. In this role, you will lead complex design initiatives from napkin sketch through full-scale manufacturing, combining hands-on technical execution with cross-functional leadership.

This is a senior individual contributor role focused on technical depth and project accountability rather than direct people management. You will serve as a subject matter expert and go-to problem solver—influencing project direction, unblocking team members, and representing engineering during strategic supplier evaluations or technical due diligence.

Core Responsibilities

Project & Technical Leadership

• Guide cross-functional project teams through full development lifecycles, establishing schedules, tracking deliverables, and maintaining engineering quality standards.
• Serve as a technical mentor to junior and mid-level engineers, coaching them through complex mechanical challenges, design trade-offs, and design-for-manufacturing (DFM) principles.
• Lead root-cause analyses and technical troubleshooting for critical product and quality issues.
• Act as a technical representative for external engagements, including technical due diligence for M&A evaluations and collaboration with domestic and international manufacturing partners.
• Drive mechanical architecture, detailed CAD modeling, component selection, and drawing release for new products and major revisions.
• Generate differentiated intellectual property, participate in patent brainstorming, and support IP strategy initiatives.
• Build, assemble, and evaluate functional prototypes to rapidly validate concepts before tooling commitment.

Validation & Production Launch

• Partner closely with testing and validation teams to define test plans, review sample performance, and resolve failure modes discovered during testing.
• Collaborate directly with toolmakers, fabricators, and assembly plants to transition designs seamlessly into high-yield production.

Candidate Profile

• Education: Bachelor's degree in Mechanical Engineering, Product Design, or a related discipline.
• Experience: 7+ years of hands-on mechanical and product design engineering experience, with a track record of launching commercial products.
• Project Ownership: Proven ability to manage multi-stakeholder design projects to completion while holding team members accountable without direct supervisory authority.
• Technical Depth: Deep working knowledge of mechanism design, materials science (plastics, metals, elastomers), tolerance stack-up analysis, and diverse manufacturing processes (casting, molding, stamping, machining).
• Tools & Software: Advanced proficiency in 3D parametric CAD modeling and standard productivity suites (Google Workspace or Microsoft Office).
• Communication & Collaboration: Exceptional communication skills with the poise to navigate high-stakes supplier reviews, cross-departmental initiatives, and executive-level project check-ins.

Work Environment & Physical Demands

• Schedule: Full-time, standard engineering workload (typically 40-45 hours per week based on project deliverables).
• Hands-On Environment: Active shop-floor engagement involving prototype assembly, inspection, and light fabrication using hand and power tools (saws, drills, grinders).
• Physical Requirements: Ability to lift, move, and position components weighing up to 50 lbs, with standard mobility required to evaluate warehouse, shop, and testing environments.
• Travel: Periodic domestic and international travel required to support supplier integrations, factory visits, or acquisition assessments.