Senior Mechanical Design Engineer

Red Frog Solutions; Wichita (KS); On-site; USD 126,000 - 154,000; Full time

Job summary

Red Frog Solutions in Wichita, KS, seeks a hands-on Senior Mechanical Design Engineer to own cradle-to-grave design of electromechanical systems, including motors, actuators, and geartrains for aerospace, defense, and industrial use. You will develop 3D CAD models, perform tolerancing and structural analysis, and collaborate with electrical, manufacturing, quality teams to drive prototypes, testing, and production release from concept through qualification.

This role requires U.S.

Qualifications

• BS in Mechanical Engineering or related discipline.
• 5+ years of mechanical product design experience with electromechanical actuators, motors, or geartrains.
• Experience with tolerance stack-up analysis, GD&T, materials selection, and design for manufacturability.
• Experience from concept to prototype, testing, qualification, and production.
• Hands-on troubleshooting of prototype and production hardware.
• Experience with structural/stress analysis.
• Ability to collaborate with manufacturing, electrical, quality, test, suppliers, and customers.
• U.S. Person required for export-control compliance.

Responsibilities

• Design and develop mechanical components and assemblies for motors, actuators, geartrains, and related electromechanical products.
• Develop 3D CAD models, detailed drawings, specifications, BOMs, and complete engineering drawing packages.
• Design and evaluate gears, shafts, bearings, housings, interfaces, seals, and other precision mechanical components.
• Perform tolerance stack-ups, structural/stress analysis, material and finish selection, and component selection.
• Design for reliability, manufacturability, assembly, durability, and long-term product performance.
• Work with electrical engineers to integrate motors, sensors, feedback devices, electronics, and mechanical packaging into complete electromechanical systems.
• Support prototype builds, qualification and environmental testing, root-cause investigations, and design improvements.
• Troubleshoot mechanical and electromechanical issues involving prototype and production hardware.
• Support pilot builds, transition into manufacturing, sustaining engineering, and continuous product improvement.
• Work directly with manufacturing, quality, test, suppliers, customers, and other engineering disciplines to resolve technical issues and advance designs.

Skills

Mechanical design

GD&T

Tolerance analysis

3D CAD

Prototyping

Qualification testing

Electromechanical systems

Collaboration

Education

BS in Mechanical Engineering

Tools

Autodesk Inventor

Autodesk Nastran

Ansys

Mathcad

Job description

Senior Mechanical Design Engineer - Electromechanical Systems

Up to $140K Base Salary

About the Role

We are seeking a hands‑on Senior Mechanical Engineer to design and develop motors, actuators, geartrains, and other high‑reliability electromechanical products used in aerospace, defense, and industrial applications.

This is a true product design role with cradle-to-grave engineering ownership. You will be involved in everything from initial mechanical design and analysis through prototyping, qualification, production release, troubleshooting, and sustaining engineering.

The ideal candidate has direct experience designing electromechanical actuators, electric motors, gearboxes/geartrains, rotating equipment, or similar precision electromechanical products and understands how components such as gears, shafts, bearings, housings, seals, and mechanical interfaces work together as a complete system.

Requirements

BS in Mechanical Engineering or related engineering discipline

5+ years of recent mechanical product design experience involving electromechanical actuators, motors, geartrains, rotating equipment, or comparable high‑reliability products

Strong experience with geartrain/gearbox design, shafts, bearings, housings, and precision mechanical assemblies

Strong knowledge of tolerance stack‑up analysis, GD&T, material selection, and design for manufacturability

Experience taking hardware from concept and detailed design through prototype, testing, qualification, and production

Hands‑on experience troubleshooting prototype and production hardware

Experience performing or supporting structural/stress analysis

Ability to work closely with manufacturing, electrical engineering, quality, test, suppliers, and customers

U.S. Person required for export‑control compliance

Nice‑to‑Haves

Experience designing electromechanical actuators or electric motor assemblies

Experience with BLDC/DC/AC motors, servo systems, or motion‑control products

Experience with lubrication, sealing, FMEA, MTBF, and reliability analysis

DO-160 and/or MIL‑STD‑810 qualification experience

Experience with Autodesk Inventor, Autodesk Nastran, Ansys, Mathcad, or similar engineering tools

Experience supporting environmental and qualification testing

Responsibilities

Design and develop mechanical components and assemblies for motors, actuators, geartrains, and related electromechanical products

Develop 3D CAD models, detailed drawings, specifications, BOMs, and complete engineering drawing packages

Design and evaluate gears, shafts, bearings, housings, interfaces, seals, and other precision mechanical components

Perform tolerance stack‑ups, structural/stress analysis, material and finish selection, and component selection

Design for reliability, manufacturability, assembly, durability, and long‑term product performance

Work with electrical engineers to integrate motors, sensors, feedback devices, electronics, and mechanical packaging into complete electromechanical systems

Support prototype builds, qualification and environmental testing, root‑cause investigations, and design improvements

Troubleshoot mechanical and electromechanical issues involving prototype and production hardware

Support pilot builds, transition into manufacturing, sustaining engineering, and continuous product improvement

Work directly with manufacturing, quality, test, suppliers, customers, and other engineering disciplines to resolve technical issues and advance designs