Senior Mechanical Engineer, Precision HVAC Sensors

Ralliant; Boxborough (MA); On-site; USD 92,000 - 171,000; Full time

Job summary

Gems Setra, a leading global supplier of sensing and monitoring technologies, seeks a Senior Mechanical Engineer to own mechanical architecture for precision HVAC/environmental sensors. You will ensure robustness under demanding conditions and collaborate across Electrical, Firmware, and Manufacturing to deliver reliable sensing solutions.

You will drive design improvements, mentor teams, and contribute to DFMEA while aligning with product lifecycle goals and manufacturing constraints.

Qualifications

• Bachelor’s degree with 8+ years or master’s with 5+ years in Mechanical Engineering.
• Strong background in sensor design for HVAC, building automation, industrial, or environmental monitoring.
• 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 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 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

Sensor design

HVAC sensing

Piezoresistive/Capacitive MEMS

Differential pressure sensing

Education

Bachelor’s degree in Mechanical Engineering

Master’s degree (preferred)

Tools

SolidWorks

Creo

GD&T

Job description

Gems Setra, a leading global supplier of sensing and monitoring technologies, seeks a Senior Mechanical Engineer to own mechanical architecture for precision HVAC/environmental sensors. You will ensure robustness under demanding conditions and collaborate across Electrical, Firmware, and Manufacturing to deliver reliable sensing solutions.

You will drive design improvements, mentor teams, and contribute to DFMEA while aligning with product lifecycle goals and manufacturing constraints.