Senior Mechanical Engineer, Precision HVAC Sensors

Gems Setra; Boxborough (MA); On-site; USD 83,000 - 155,000; Full time

Job summary

Gems Setra, a leading sensing technology provider in Boxborough, MA, seeks a Senior Mechanical Engineer to own the mechanical architecture and design of precision sensors for HVAC and environmental monitoring. You will develop components, assemblies, and packaging that meet stringent accuracy, reliability, and manufacturability requirements.

You will lead prototyping, qualification, and DFMEA, collaborating with Electrical, Firmware, Test, and Manufacturing teams to optimize performance and cost

Qualifications

• Bachelor’s degree with 8+ years experience in Mechanical Engineering.
• Strong background in sensor design for HVAC, building automation, industrial, or environmental monitoring applications.
• Proficiency in SolidWorks, Creo, or equivalent CAD tools, including advanced mechanical design and GD&T.
• Experience designing housings and sensing structures using metals, polymers, elastomers, and environmental-grade materials.
• Strong understanding of thermal behavior, airflow dynamics, sealing, and environmental protection (IP ratings).
• Experience designing for manufacturing methods used in HVAC/environmental sensors: machined parts, injection-molded plastics, die-cast housings, welded/brazed sensing elements.
• Preferred: knowledge of differential pressure sensing, piezoresistive or capacitive elements, MEMS, and sensor packaging in harsh environments.
• A collaborative mindset, strong communication skills, and a passion for building high-performance, reliable sensing products.

Responsibilities

• Design and develop mechanical components and assemblies for HVAC and environmental monitoring sensors (pressure transducers, differential pressure sensors, flow sensors, IAQ/IEQ devices).
• Create detailed CAD models, drawings, GD&T, material specs, and tolerance analyses optimized for accuracy and manufacturability.
• Perform FEA and thermal analysis to validate mechanical robustness under HVAC-relevant conditions (airflow, vibration, humidity, thermal drift).
• Lead prototyping, environmental qualification, and reliability testing (pressure cycling, humidity/condensation testing, thermal shock, leak testing).
• Optimize sensor mechanical interfaces for easy installation in air ducts, cleanrooms, mechanical rooms, and building automation systems.
• Partner with Electrical, Firmware, Test Engineering, and Manufacturing on sensor integration and verification.
• Drive VAVE, cost reduction, and design improvements across the product lifecycle.
• Provide technical leadership, mentoring, and support for both NPI and sustaining engineering activities.
• Lead and participate in DFMEA for new and existing products
• Manage multiple small to medium sized engineering focused projects, including schedule and financial tracking

Skills

Mechanical design

CAD modeling

GD&T

FEA

Thermal analysis

Sensor packaging

Cross-functional collaboration

Leadership / mentoring

Education

Bachelor’s degree in Mechanical Engineering

Master’s degree in Mechanical Engineering

Tools

SolidWorks

Creo

Job description

Gems Setra, a leading sensing technology provider in Boxborough, MA, seeks a Senior Mechanical Engineer to own the mechanical architecture and design of precision sensors for HVAC and environmental monitoring. You will develop components, assemblies, and packaging that meet stringent accuracy, reliability, and manufacturability requirements.

You will lead prototyping, qualification, and DFMEA, collaborating with Electrical, Firmware, Test, and Manufacturing teams to optimize performance and cost