Senior Mechanical Design Engineer Rugged Sensor Systems

ADP, Inc.; Coppell (TX); On-site; USD 120,000 - 150,000; Full time

Benefits offered by this job

Paid Time Off

Life insurance

Casual workplace

401K with company match

Job summary

Rochester Sensors, an Amphenol Company, seeks a Senior Mechanical Design Engineer in Coppell, TX to architect and develop rugged mechanical systems for liquid level sensing in harsh industrial environments.

You will own the complete design lifecycle from concept through production, including prototyping, testing, and design iteration, with focus on vibration resistance, sealing, and electronics packaging.

Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering.
• 8+ years designing rugged industrial or automotive products.
• Proven track record developing mechanical systems for sensors or instrumentation.
• Experience in harsh-environment product design, ruggedized packaging, vibration/fatigue resistance, sealing, and materials for extreme environments.
• Advanced experience with 3D CAD systems.
• Experience using FEA tools for structural, vibration, and thermal analysis.
• Experience in automotive-grade development systems (APQP, DFMEA/PFMEA, environmental validation, IATF 16949).

Responsibilities

• Design the mechanical architecture for advanced liquid level sensing systems, including: guided wave radar probes, capacitive sensing structures, and ultrasonic sensor housings.
• Develop sensor designs capable of surviving years of operation in extreme duty cycles.
• Create mechanical systems that withstand: severe vibration and mechanical shock, extreme temperature ranges (– 40°C to +125°C+), fluid exposure and chemical attack, and dust, contamination, and pressure variations.
• Focus on areas including: structural integrity, sealing and environmental protection, electronics packaging, probe and waveguide design, and material selection for durability and corrosion resistance
• Perform deep failure analysis and root cause investigations.
• Solve problems related to: vibration-induced fatigue, thermal expansion mismatches, fluid interaction with sensing structures, long-term reliability of ruggedized electronics packaging
• Design and perform FEA analysis on designs for rapid failure analysis
• Own the mechanical design from concept through production.
• Lead prototype development, testing, and design iteration.
• Drive design decisions balancing performance, reliability, manufacturability, and cost.
• Work within automotive-grade development systems including: APQP, DFMEA / PFMEA, design verification and validation testing
• Support development processes aligned with IATF 16949 quality systems.

Skills

3D CAD

Rugged design

FEA

Education

Bachelor’s or Master’s degree in Mechanical Engineering

Tools

APQP

DFMEA/PFMEA

IATF 16949

Environmental testing

Job description

Rochester Sensors, an Amphenol Company, seeks a Senior Mechanical Design Engineer in Coppell, TX to architect and develop rugged mechanical systems for liquid level sensing in harsh industrial environments.

You will own the complete design lifecycle from concept through production, including prototyping, testing, and design iteration, with focus on vibration resistance, sealing, and electronics packaging.