Senior Mechanical Engineer, NPI & Molded Parts

Nelson Miller Group

Northern (KY)

Hybrid

USD 140,000 - 155,000

Full time

14 days+

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Benefits offered by this job

Medical, dental and vision coverage

401(k) Retirement Savings Plan

Paid holidays

Sick leave

Vacation time

Employee assistance program

Job summary

Nelson Miller Group in Kentucky is seeking a Principal Mechanical Engineer to drive complex mechanical designs from concept to production. You will mentor a small team, own NPI, and manage EVT/DVT/PVT, prototyping, and manufacturing readiness.

You will collaborate with mold makers, contract manufacturers and suppliers to optimize design and tooling. This role requires hands-on leadership, CAD/FEA expertise, and a strong focus on DFM through production launch.

Qualifications

Bachelor’s degree in Mechanical Engineering or related field; Master’s preferred.
Minimum of 10 years mechanical design experience, with at least 5 years in NPD; leadership experience.
Experience in injection-molded part design, tooling considerations, and DFM/ DFA through production launch.
Strong proficiency in 3D CAD and FEA tools (SolidWorks/SolidWorks Simulation, Creo, NX, or equivalent).
Demonstrated ability to lead small engineering teams or project groups.
Deep understanding of materials, mechanics, GD&T, and manufacturing processes.
Experience launching new production at the factory floor level.
Experience working with overseas suppliers.
Knowledge of PLM systems, structured documentation practices, and medical device / ISO 8 cleanroom requirements.
Travel: Ability to travel approximately 10%.

Responsibilities

Lead engineering direction, design decisions, and technical strategy for new customer-driven injection molded products.
Review customer concepts, CAD models, assemblies, drawings, and technical requirements to advise on DFM, tooling approach, cost, and production readiness.
Own mechanical development from concept through validation testing (EVT/DVT/PVT) and production launch.
Support quoting of tooling and production piece pricing by assessing part complexity, materials, tolerances, cycle time, cavitation, and secondary operations.
Mentor and guide a small team of mechanical engineers and designers; review work and elevate design quality.
Build and evaluate prototypes using machining, 3D printing, and soft tooling.
Partner cross-functionally with engineering, sales, manufacturing, quality, and supply chain teams to ensure seamless integration.
Work directly with mold makers, contract manufacturers, and suppliers to optimize part design, tooling design, and mold construction.
Perform tooling DFM reviews with suppliers, including gate/runner layout, parting lines, shutoffs, venting, ejection, mold flow, and inspection requirements.
Lead tooling launch, sampling, validation, and production release on the manufacturing floor, including ISO 8 cleanroom molding when applicable.
Improve design processes, standards, and best practices across the engineering organization.
Adhere to federal and state regulations.
Adhere to all company policies, processes, and procedures.
Perform other duties as requested, directed, or assigned.