Senior Mechanical Engineer

Actalent; North Reading (MA); On-site; USD 90,000 - 135,000; Full time

Job summary

Actalent in Massachusetts seeks a self-motivated Mechanical Engineer to lead product design from concept to prototype, focusing on camera and sensor systems.

You will create 3D models in SolidWorks, integrate electro-mechanical components, perform thermal analyses with Ansys, and ensure manufacturability through DFMA and DFA.

Qualifications

• 5+ years mid-career experience in mechanical product design.
• Experience with camera/sensor systems preferred.
• Proficient in SolidWorks and GD&T.
• Strong knowledge of DFx (DFM/ DFA).
• Experience with welding and weldment design.

Responsibilities

• Design and develop mechanical products from concept through prototype, focusing on camera/sensor solutions.
• Create detailed 3D models and assemblies in SolidWorks, including sheet metal parts and weldments.
• Integrate mechanical, electrical, and software components with cross-functional teams.
• Develop and manage mechanical design requirements for reliability and quality.
• Perform thermal analyses to address thermal management in camera/sensor systems.
• Apply GD&T for tolerance stack-up analyses and proper manufacturability.
• Create manufacturing drawings for fabrication and assembly.
• Lead testing activities and root cause analyses during development.
• Prototype and iterate designs based on test results and manufacturing input.
• Collaborate with fabrication and external vendors to address production constraints.

Skills

Weldment design

Tolerance stack-up analysis

GD&T

Sheet metal design

Design for manufacturability (DFM)

Design for assembly (DFA)

Prototyping

Troubleshooting mechanical issues

Electromechanical assemblies

Vendors collaboration

Tools

SolidWorks

Ansys

Job description

This role offers an opportunity for a self-motivated Mechanical Engineer to work as a Product Design Engineer and lead the development of innovative, camera- and sensor-focused products from concept through prototype. You will create cutting-edge mechanical designs that integrate cameras, sensors, and supporting hardware, with particular emphasis on thermal management, optics considerations, and robust electromechanical assemblies. In this fast-paced environment, you will collaborate with cross-functional teams, drive projects independently, and ensure that every design meets demanding performance, quality, and manufacturability standards.

Responsibilities

• Design and develop innovative mechanical products from initial concept through prototype, with a focus on camera-focused and sensor-focused solutions.
• Create detailed 3D models and assemblies in SolidWorks, including complex sheet metal parts, weldments, and larger mechanical stations or electromechanical equipment.
• Integrate mechanical, electrical, and software components into cohesive product designs by collaborating closely with cross-functional engineering teams.
• Develop, document, and manage mechanical design requirements to ensure products meet or exceed performance, reliability, and quality targets.
• Perform thermal simulations and analyses to address thermal management challenges in camera and sensor systems.
• Conduct tolerance stack-up analysis and apply GD&T principles to ensure proper fit, function, and manufacturability of components and assemblies.
• Create clear, accurate, and detailed manufacturing drawings that support efficient fabrication and assembly processes.
• Plan and execute testing activities to validate design assumptions, including root cause analysis and systematic problem-solving when issues arise.
• Lead hands-on prototyping and iterative design cycles, refining concepts based on test results, user feedback, and manufacturing input.
• Work directly with fabrication and manufacturing teams, as well as external vendors, to address practical fabrication constraints and optimize designs for production.
• Troubleshoot mechanical issues during build, assembly, and integration, providing timely solutions and design updates as needed.
• Apply design for manufacturability (DFM) and design for assembly (DFA) principles throughout the product development process.
• Drive projects forward independently with minimal supervision, managing priorities and deliverables to meet schedule and quality expectations.
• At least 5 years of mid-career experience in mechanical product design, preferably with a focus on camera and sensor-based systems.
• Strong mechanical engineering and mechanical design background, including experience with larger mechanical stations, equipment, or electromechanical assemblies.
• High proficiency in SolidWorks for 3D CAD modeling, assembly design, and detailed drawing creation.
• Proficiency with Ansys or similar tools for thermal simulations and related engineering analysis.
• Strong sheet metal design experience, including forming, bending, and joining considerations.
• Proven experience in weldment and welded assembly design for robust mechanical structures.
• Strong skills in creating detailed manufacturing drawings that clearly communicate specifications and tolerances.
• Advanced knowledge of GD&T and the ability to perform comprehensive tolerance stack-up analyses.
• Hands-on prototyping experience and comfort with iterative design cycles.
• Solid understanding of design for manufacturability (DFM) and design for assembly (DFA), including practical fabrication and production constraints.
• Experience working directly with fabrication and manufacturing teams, as well as vendors, to support production and resolve issues.
• Demonstrated ability to troubleshoot mechanical issues during build, assembly, and integration and implement effective corrective actions.
• Experience with testing, structured problem-solving, and root cause analysis in a product development environment.
• Top priority: weldment / welded assembly design experience
• Experience designing larger mechanical stations, equipment, or electromechanical assemblies
• Strong GD&T and tolerance stack-up analysis
• Hands-on prototyping and iterative design experience
• Good understanding of DFM/DFA and practical fabrication constraints
• Experience working directly with fabrication/manufacturing teams and vendors
• Ability to troubleshoot mechanical issues during build, assembly, and integration
• Prefer candidates who can clearly describe sheet metal and welded structures they personally designed, not just list those skills on the resume

Additional Skills & Qualifications

• Experience in product design specifically for camera-focused and sensor-focused solutions.
• Familiarity with optics design principles and machine vision systems.
• Strong understanding of production design principles and lifecycle considerations from prototype to full-scale manufacturing.
• Ability to work independently with minimal supervision while effectively collaborating within cross-functional teams.
• Comfort operating in a fast-paced, dynamic environment and managing multiple priorities.
• Clear communication skills for documenting requirements, presenting design decisions, and coordinating with engineering and manufacturing stakeholders.

This position operates in a fast-paced engineering and product development environment focused on mechanical, electromechanical, and camera/sensor-based systems. You will primarily work with modern engineering tools such as SolidWorks for 3D CAD and Ansys for thermal simulations, and you will regularly collaborate with electrical, software, and manufacturing teams. The role involves both office-based design work and hands-on activities in prototyping and fabrication areas, including close interaction with internal fabrication and assembly teams and external vendors. The environment emphasizes practical design for manufacturability and assembly, iterative prototyping, and rigorous testing to achieve high-performance, production-ready products.