Senior Mechanical Engineer

Field Theory Consulting Inc.; Chicago (IL); On-site; USD 85,000 - 120,000; Full time

Benefits offered by this job

Medical coverage

Dental & Vision

401(k) match

Paid time off

Paid holidays with inclusive calendar

Wellness coaching

Company events

Job summary

Field Theory Consulting Inc. in Chicago is seeking a Senior Mechanical Engineer to lead the design and development of next-generation products from concept through production.

You will partner with design, electrical, manufacturing and quality teams to deliver robust, manufacturable solutions, mentor junior engineers, and document designs with precision.

The role emphasizes rigorous design reviews, tolerance analysis, FEA, rapid prototyping, and hands-on work in the lab or on the shop floor.

Qualifications

• 5+ years of experience in mechanical engineering.
• Bachelor's degree in Mechanical Engineering or related field.
• Proficiency in CAD software (SolidWorks preferred) and GD&T fundamentals.
• Understanding of materials, manufacturing processes and DFM principles.
• Experience with FEA and other simulation/analysis tools.
• Experience with rapid prototyping (3D printing, CNC), test rig development, and MIL Standards.
• Demonstrated ability to solve ambiguous, undefined problems independently.

Responsibilities

• Lead mechanical design and development across the full product lifecycle, from concept through production release.
• Design, analysis, and validation of mechanical components, assemblies, and antenna systems.
• Conduct tolerance analysis, FEA, and DFM/DFA reviews to ensure designs are robust and manufacturable.
• Build and test prototypes with 3D printers, LPKF, and hand modifications.
• Troubleshoot issues and drive root-cause investigations.
• Collaborate with electrical, firmware, industrial design, and manufacturing teams to deliver integrated solutions.
• Manage multiple projects and priorities simultaneously in a dynamic, fast-moving environment.
• Create and maintain detailed CAD models, drawings, BOMs, and design documentation.
• Support supplier selection, DFM feedback, and production ramp-up.
• Mentor junior engineers and contribute to engineering best practices and process improvements.

Skills

Mechanical design

CAD: SolidWorks

GD&T fundamentals

FEA

Prototype testing

Cross-functional collaboration

Project management

Education

Bachelor's degree in Mechanical Engineering or related field

Tools

SolidWorks

Job description

Ready to love what you do? We're on the lookout for talented, driven people to grow with us!

You’ll love Field Theory’s Benefits:

• Company pays 100% of the Employee Premium for Medical Healthcare and also 100% Company Paid Premium for Medical Healthcare for the first dependent and 50% Company Paid Premium for Medical Healthcare for each dependent thereafter.
• Dental and Vision Benefits
• 401(k) with Company Match
• Paid Time Off
• Paid Holiday with an Inclusive Calendar,
• Wellness Coaching
• Company Events

Current Opening:

Senior Mechanical Engineer

Reports To: CEO / Founding Engineer

Employment Type: Full-Time

Salary Range (dependent upon experience): $85,000 to $120,000

About the Role

We're looking for an experienced Senior Mechanical Engineer to join our team and help drive our next generation of product development. This role is ideal for someone who thrives in a fast-paced environment, brings structure and rigor to complex problems, and has a proven track record of taking products from concept through production. You'll work closely with cross-functional teams — design, electrical, manufacturing, and quality — to develop innovative, manufacturable, and reliable mechanical solutions. If you're the kind of engineer who digs in until you find the root cause, keeps meticulous documentation, and stays calm when priorities shift, we want to hear from you.

What You’ll Do

• Lead mechanical design and development efforts across the full product lifecycle, from concept through production release
• Design, analysis, and validation of mechanical components, assemblies, and antenna systems
• Conduct tolerance analysis, FEA, and DFM/DFA reviews to ensure designs are robust and manufacturable
• Build and test prototypes with 3D printers, LPKF, and hand modifications
• Troubleshoot issues and drive root-cause investigations
• Collaborate with electrical, firmware, industrial design, and manufacturing teams to deliver integrated solutions
• Manage multiple projects and priorities simultaneously in a dynamic, fast-moving environment
• Create and maintain detailed CAD models, drawings, BOMs, and design documentation
• Support supplier selection, DFM feedback, and production ramp-up
• Mentor junior engineers and contribute to engineering best practices and process improvements

What We’re Looking For

• 5+ years of experience in mechanical engineering, with a strong history of designing products from concept to production
• Bachelor's degree in Mechanical Engineering or related field (advanced degree a plus)
• Proficiency in CAD software (SolidWorks preferred) and strong GD&T fundamentals
• Understanding of materials, manufacturing processes (injection molding, sheet metal, machining, casting, etc.), and DFM principles
• Experience with FEA and other simulation/analysis tools
• Experience with rapid prototyping (3D printing, CNC), test rig development, and MIL Standards
• Demonstrated ability to solve ambiguous, undefined problems independently
• Highly organized and structured approach to project and time management
• Exceptional attention to detail, especially in documentation, tolerancing, and design reviews
• Comfortable working in a fast-paced, iterative environment with shifting priorities
• Strong communication skills and experience collaborating cross-functionally
• A hands‑on mindset — comfortable in the lab or on the shop floor, not just at a desk

Nice to Have

• Experience with regulated or highly reliable product categories (medical, aerospace, automotive, consumer hardware)
• Knowledge of antenna theory
• Background mentoring or leading small project teams

Field Theory is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.