Senior Mechanical Engineer

Aegis Sortation; Blue Ridge Manor (KY); On-site; USD 110,000 - 150,000; Full time

Benefits offered by this job

Competitive salary

Health insurance

401k

Paid time off

10 Company Holidays

Professional development opportunities

Job summary

Aegis Sortation is seeking a Senior Mechanical Engineer - Product Design to drive complex mechanical designs for high‑performance material handling systems and to own testing, data acquisition, and performance analysis. You will mentor junior engineers and help advance autonomous facility goals for 2030.

Design assemblies in SolidWorks, run simulations, lead cross‑functional teams, estimate effort, and contribute to DFMEA and Safety Risk Analyses.

Qualifications

• Minimum 10 years of progressive mechanical design experience in industrial automation or material handling.
• Direct experience with freight/parcel logistics or high-throughput systems preferred.
• Bachelor’s degree in Mechanical Engineering; Master’s preferred.
• Proven track record delivering production-ready designs meeting performance targets.
• Hands-on experience with conveyors, sortation, or automated packaging/bagging systems.
• Exposure to vision-guided or adaptive conveyance technologies; collaboration with controls/electrical teams.

Responsibilities

• Create complex mechanical designs (assemblies/subsystems) using SolidWorks.
• Perform advanced stress/deflection analyses and validate against performance requirements.
• Lead testing, data acquisition, and analysis; develop instrumentation and collect performance data.
• Own user stories and lead cross-functional teams to meet Stage Gate milestones.
• Estimate effort, create timelines, and drive resources to schedules.
• Mentor Level 1-2 engineers on design best practices, DFMEA, and testing rigor.
• Contribute to backlog refinement, sprint planning, and continuous improvement.

Skills

Mechanical design

Team mentoring

Cross-functional leadership

Testing & data analysis

DFMEA

Safety risk analysis

Data acquisition

Education

Bachelor's degree in Mechanical Engineering

Master's degree in Mechanical Engineering

Tools

SolidWorks

SolidWorks Simulation

Python

MATLAB

Microsoft Teams

Job description

About Aegis Sortation

At Aegis, our purpose is clear: to

Brief Description

About Aegis Sortation

At Aegis, our purpose is clear: to create raving fans through expert innovation in intralogistics. Our team combines innovative thinking with deep industry expertise to deliver solutions for projects of all sizes, throughputs, and complexities.

Aegis Sortation is a leader in the intralogistics technology and innovation space. Our expertise spans E-Commerce, Freight and Parcel, and Warehouse and Distribution. As a prime integrator, we have a team capable of conceptualizing and laying out complex systems, and completing detailed design engineering, procurement, and field installation across various project platforms. Our commitment to integrating excellence throughout the project life cycle sets us apart, delivering automation solutions to businesses ranging from local service providers to international logistics giants.

Overview

The Senior Mechanical Engineer - Product Design drives complex mechanical design for high-performance material handling systems (conveyors, sorters, and autonomous parcel handling equipment) while leading testing, data acquisition, and performance analysis to de-risk Stage Gate deliverables. You will balance deep technical ownership with mentoring Level 1–2 team members and advancing our BHAG of fully autonomous facilities by 2030. You will also own the design-to-validation loop for systems that directly improve uptime, throughput, and package integrity in demanding parcel environments.

Primary Responsibilities

• Create complex mechanical designs (assemblies, subsystems, and components) from specifications, napkin sketches, or customer requirements using SolidWorks.
• Perform advanced stress, strain, deflection, and dynamic analyses using SolidWorks Simulation; validate designs against parcel handling performance requirements.
• Lead testing, data acquisition, and analysis: Develop and execute detailed test plans for prototypes and pilot systems; specify and implement instrumentation (load cells, encoders, accelerometers, high-speed cameras, DAQ systems); collect, process, and analyze performance data (throughput, jam rates, package integrity, energy consumption, MTBF) using Python/MATLAB or equivalent; produce clear reports with statistical confidence and actionable recommendations.
• Own user stories and lead cross-functional teams (mechanical, electrical, controls, manufacturing) via Microsoft Teams to meet Stage Gate milestones.
• Accurately estimate effort, create timelines, and drive internal/external resources to schedule.
• Mentor Level 1 and 2 engineers on design best practices, DFMEA, Safety Risk Analysis, and testing rigor.
• Contribute to backlog refinement, sprint planning, and retrospectives while reinforcing core values and collaborative culture.

Requirements

• Minimum 10 years of progressive mechanical design experience in industrial automation, custom machinery, or material handling systems.
• Preferred: Direct experience with freight/parcel, high-volume logistics, or distribution equipment (conveyors, sorters, automated bagging, or similar high-throughput systems).
• Bachelor’s degree in Mechanical Engineering required; Master’s preferred.
• Proven track record delivering tested, production-ready designs that exceed customer performance requirements (throughput, jam rates, package integrity, energy consumption, MTBF).
• Experience in freight, parcel, or high-throughput logistics environments.
• Hands-on work with conveyor, sortation, or automated packaging/bagging systems.
• Familiarity with high-uptime targets, MTBF analysis, or field performance validation against real parcel mixes (smalls, irregulars, polybags).
• Exposure to vision-guided or adaptive conveyance technologies.
• Collaboration experience with controls and electrical teams on instrumentation and data capture.

Benefits:

• Competitive salary
• Health insurance
• 401k
• Paid time off
• 10 Company Holidays
• Professional development opportunities

This job description describes the general nature and level of work expected of a person assigned to this position. All job requirements listed indicate the minimum level of knowledge, skills and/or ability deemed necessary to perform the job proficiently. Employees may be required to perform any other job-related duties as requested by their supervisor.

It is the policy of Aegis Sortation to provide equal employment opportunity (EEO) to all persons regardless of age, color, national origin, physical or mental disability, race, religion, creed, gender, sex, sexual orientation, gender identity and/or expression, genetic information, marital status, pregnancy or pregnancy-related condition, status with regard to public assistance, veteran status, citizenship status (if authorized to work in the U.S.), or any other characteristic protected by federal, state or local law. In addition, Aegis Sortation will provide reasonable accommodation for qualified individuals with disabilities.