Senior Mechanical Engineer - Design Lead for Safe, Innovative Parts

Bullard; Kentucky; On-site; USD 100,000 - 140,000; Full time

Job summary

The Senior Mechanical Engineer at Bullard leads mechanical design, development, verification, and lifecycle support across head protection, fire helmet, respiratory protection, and thermal imaging portfolios. You will translate customer needs into robust, manufacturable, and compliant product solutions with cross-functional teams in Lexington and Cynthiana.

Responsibilities include defining specifications, designing for injection molding, developing test plans, performing tolerance analyses, and

Qualifications

• B.S. in an Engineering discipline.
• 10 years of experience in Mechanical Engineering of new products or related.
• Excel at using CAD to design assemblies and injection-molded plastic parts.
• Experience creating and reviewing engineering drawings and using GD&T.
• Experience troubleshooting technical problems and implementing effective corrective actions.
• Experience developing test plans, conducting product testing, interpreting technical data, and presenting results clearly.
• Ability to read, understand, and apply industry standards, specifications, and compliance requirements.
• Strong understanding of manufacturing processes and DFM, especially with injection molded plastic parts.
• Self-starter with a passion for problem-solving and enthusiastic advocacy for the customers’ needs, the products, and the company

Responsibilities

• Lead the definition, documentation, design implementation, and verification of mechanical requirements for new electromechanical safety products.
• Collaborate with product managers and cross-functional teams to establish product specifications, design objectives, cost targets, deadlines, and performance requirements.
• Design plastic components and assemblies for injection molding using CAD, including development of engineering drawings and tolerance analyses.
• Develop test plans and test methods to evaluate product performance, investigate field or production issues, and verify regulatory compliance.
• Analyze test and product evaluation data and present the results.
• Lead mechanical design reviews and communicate design decisions, risks, tradeoffs, and recommendations to cross-functional stakeholders.
• Perform tolerance analysis, engineering calculations, material selection, and design risk analysis (FMEA) to ensure product safety and robustness.
• Collaborate with operations, quality, sourcing, and product management teams to support ongoing product improvements.
• Support production and quality teams by investigating, diagnosing, and resolving product and manufacturing issues.
• Participate in product compliance activities, including interpreting applicable standards and regulatory requirements.
• Become a subject matter expert in regulatory and standards product and testing requirements applicable to respiratory protection, head protection, and/or fire helmets.
• Support manufacturing process improvements and continuous improvement initiatives.
• Provide technical support for supplier, material, and component-related issues as needed.
• Mentor engineers in mechanical design, testing, problem-solving, and engineering best practices.

Skills

Mechanical design

Injection molding

GD&T

Test plans

FMEA

Cross-functional collaboration

Regulatory compliance

Problem solving

Education

B.S. in Engineering

Tools

CAD

Engineering drawings

Job description

The Senior Mechanical Engineer at Bullard leads mechanical design, development, verification, and lifecycle support across head protection, fire helmet, respiratory protection, and thermal imaging portfolios. You will translate customer needs into robust, manufacturable, and compliant product solutions with cross-functional teams in Lexington and Cynthiana.

Responsibilities include defining specifications, designing for injection molding, developing test plans, performing tolerance analyses, and