Senior Mechanical Product Engineer

FLX Solutions, Inc.; Bethlehem, Northern (Northampton County, KY); Hybrid; USD 110,000 - 140,000; Full time

Job summary

FLX Solutions, Inc. is building robotic systems to accelerate inspection and maintenance. We seek a senior mechanical engineer to lead the design of complex systems from concept through production, collaborating with electrical, software and industrial design teams.

You will mentor junior engineers, create robust 3D CAD models in SolidWorks, and drive manufacturing readiness for pilot and production units. Join a startup scaling this patented technology for defense, maritime, and industrial

Qualifications

• Bachelor's degree in mechanical engineering or related field.
• 5+ years of mechanical product design and development experience.
• Proven track record leading mechanical design from concept through production.
• Experience prototyping and integrating PCBs and electrical assemblies.
• Must be a U.S. citizen.

Responsibilities

• Lead the mechanical design process from concept through production, including system architecture and verification.
• Collaborate with Electrical, Software, and Industrial Design to develop integrated mechanical systems.
• Manage in-house assembly and pilot-unit manufacturing.
• Design 3D CAD models and ensure compliance with requirements and budgets.
• Develop detailed specifications and contribute to Quality Management System documentation.
• Liaise with customers and suppliers to ensure successful project delivery.

Skills

Mechanical design

SolidWorks

Prototyping

PCB integration

Leadership

US citizenship

Education

Bachelor's in Mechanical Engineering

Tools

3D Printing

CNC Machining

Injection Molding

Sheet Metal

Job description

FLX Solutions, Inc. builds robotic systems that make inspection and maintenance faster, safer, and more repeatable, especially in tight, hard-to-reach spaces. Our flagship platform, the FLX BOT, is a modular, handheld, snake-like articulating robotic system designed to solve one of the toughest challenges in maintenance: reaching the "last meter" in complex environments. It is already in use with the U.S. Navy, U.S. Air Force, a major DoD prime, and shipbuilders, with expanding applications across industrial, transit, and construction sectors.

We’re at the build-and-scale stage. The FLX BOT has moved from prototypes to paying customers in defense, maritime, and industrial markets, and we’re growing the team to keep up. If you want your work in the hands of real users within months, not years, and the room to shape how we build, this is the place.

Your impact will extend beyond technical execution; you will play a fundamental role in scaling our organization. By establishing engineering standards, selecting tools, and defining processes, you will mentor future team members and influence our long-term product roadmap. The foundations you build today will define the mechanical engineering excellence at FLX for years to come.

Develop products from concept to production, working closely with our clients and cross-functional teams. As a key member of the team, you will share your experience and knowledge and learn from your colleagues.

Key Responsibilities:

• Lead the mechanical design process from concept through production, including system architecture, detailed design, and verification.
• Collaborate with cross-functional teams Electrical Engineering, Software Engineering, and Industrial Design to develop integrated mechanical systems.
• Manage in-house assembly and manufacturing team for assembly of pilot units and advanced prototypes.
• Conduct technical feasibility studies to address complex design challenges.
• Design and build prototypes that meet technical requirements, client needs, and budgets.
• Develop 3D CAD models for complex mechanical systems and ensure designs meet technical, client, and regulatory requirements.
• Perform detailed product design, including the integration of electrical assemblies and complex geometries.
• Write detailed specifications and documentation, and help shape the Quality Management System itself as we build out the processes, templates, and standards that will scale with the team.
• Liaise with customers and suppliers to address project requirements and ensure successful project delivery.
• Document complete designs for manufacture and assembly.

Qualifications:

Required:

• Bachelor’s degree in mechanical engineering or a related field from a reputable institution.
• 5+ years of experience in mechanical product design and product development, preferably within a multidisciplinary team.
• Proven track record leading the mechanical design of complex systems from concept through production.
• Proficiency in 3D Solidworks software for mechanical and mechatronic system design.
• Experience with both rapid prototyping and traditional manufacturing techniques, including 3D printing, CNC machining, injection molding, and sheet metal design.
• Hands-on experience prototyping and integrating PCBs and electrical assemblies into mechanical systems.
• Excellent problem-solving skills, attention to detail, and ability to lead and work within a team.
• Strong verbal and written communication skills; ability to manage and work effectively with team members, customers, and suppliers.
• Able to mentor and grow the abilities of junior engineers and technicians to complete complex tasks
• Must be a U.S. Citizen.

Preferred:

• Experience leading mechanical design projects and mentoring technicians and junior engineers.
• Familiarity with Python, ROS (or similar) and C/C++.
• Experience with automation, robotics, or mechatronic system design.
• Experience working in a startup environment or as a member of a small team.
• Ability to leverage modern AI tools to accelerate engineering development

FLX Solutions is a funded startup looking to change the robotics industry with our patented FLX BOT hardware and software solution.