Staff Engineer

United Alloy Inc; Janesville (WI); On-site; USD 110,000 - 150,000; Full time

Job summary

United Alloy is seeking a Staff Engineer to serve as a technical SME for structural and mechanical systems, leading complex projects from concept to manufacturing. You'll drive innovation, develop scalable product architectures, perform CAD/FEA analyses, and guide cross‑functional teams to cost-effective, reliable designs.

Qualifications include a BS in mechanical engineering, 10+ years’ experience, CAD/FEA proficiency, and strong leadership and communication skills. Master’s and PE are a plus.

Qualifications

• Bachelor’s degree in mechanical engineering or related field; Master’s degree preferred; PE certification a plus.
• 10+ years of experience in product design and development, including structural design and materials selection.
• Experience with 3D CAD software, FEA and other simulation tools.
• Strong understanding of manufacturing processes, materials and assembly techniques.
• Excellent problem-solving skills, analytical rigor, and attention to detail.
• Demonstrate professionalism, accountability, and the desire for challenges.
• Effective communication and leadership abilities for cross-functional presentations.
• Willingness to take on non-traditional tasks to accomplish company goals.
• 12 Expected Behaviors of Actively Engaged Person – 100% Responsible, Trustworthy, Team Player, Clear Communicator, Empathy, Humility, Emotional Self‑Control, Resolves Conflict Directly, Positive Attitude, Respects Others, Problem Solver, and Agile.

Responsibilities

• Actively researches and evaluates new materials, manufacturing techniques and engineering methodologies.
• Identifies, creates and refines mechanical systems, materials, components, and products using CAD/FEA to evaluate performance.
• Develops product architecture and modular design strategies for platform scalability and reuse.
• Conducts feasibility studies, engineering risk assessments and cost-benefit analyses.
• Leads root cause analysis and corrective actions for field issues and quality escapes.
• Provides guidance mentorship to junior engineers.
• Ensures compliance with regulatory, industry, and customer requirements.

Skills

Mechanical design

Engineering leadership

3D CAD

FEA

Materials selection

Problem solving

Communication

Accountability

Team leadership

Education

Bachelor's in Mechanical Engineering

Master's degree preferred

PE certification a plus

Tools

3D CAD

FEA software

Job description

• On-site
• Full-Time
• Requisition #: STAFF001766

Description

The staff engineer serves as a technical subject matter expert for structural and mechanical systems. The right candidate must have the ability to lead complex projects and drive innovation into the design and manufacturing processes. This role is critical to the successful design, development, and implementation of United Alloy’s cutting-edge products.

WHAT YOU'LL DO

• Actively researches and evaluates new materials, manufacturing techniques and engineering methodologies utilizing analytical tools, including AI generative design to drive continuous improvement, cost reduction, and efficiency gains.
• Identifies, creates and refines mechanical systems, materials, components, and products using CAD, FEA, and other simulation tools to evaluate product and system performance, benchmark against legacy designs, and validate functionality, safety, and reliability prior to manufacture.
• Develops product architecture and modular design strategies that enable platform scalability, component reuse, and interchangeability across product lines, while optimizing material selection performance, cost, and manufacturability.
• Conducts feasibility studies, engineering risk assessments and cost-benefit analyses to support new product and process development projects.
• Leads root cause analysis and develops corrective and preventive action solutions for field issues, warranty claims, and quality escapes, partnering with design, quality and manufacturing to drive permanent resolution.
• Provides guidance mentorship to junior engineers to support development of their technical competencies.
• Ensures compliance with all applicable regulatory, industry, and customer engineering requirements and standards.

WHAT YOU'LL BRING

• Bachelor’s degree in mechanical engineering or related field required; Master’s degree preferred. PE certification a plus.
• 10+ years of experience in product design and development, including structural design, analysis and materials selection.
• Experience with 3D CAD software, FEA and other simulation tools.
• Strong understanding of manufacturing processes, materials and assembly techniques.
• Excellent problem-solving skills, analytical rigor, and attention to detail.
• Demonstrate professionalism, accountability, and the desire for challenges.
• Effective communication and leadership abilities, including the ability to present technical findings to cross‑functional stakeholders.
• Willingness to take on non‑traditional tasks, roles, responsibilities, and challenges needed to accomplish company goals.
• 12 Expected Behaviors of Actively Engaged Person – 100% Responsible, Trustworthy, Team Player, Clear Communicator, Empathy, Humility, Emotional Self‑Control, Resolves Conflict Directly, Positive Attitude, Respects Others, Problem Solver, and Agile.

ABOUT UNITED ALLOY
United Alloy is a preferred designer, manufacturer and powder coater of certified metal tanks, skids, frames, trailers, chassis, and related products crafted to world‑class quality standards in strategic partnership with Fortune 500 OEM customers. UA products are proudly “Made in the USA”. In addition to being made in the USA, UA is also 9001 certified, and has been recognized as a WBENC woman/minority owned business.

CULTURE
United Alloy empowers and entrusts our employees to manage the responsibilities of both their work and home lives. We are an agile team that produces extraordinary results, setting the standard in safety, quality, productivity, and profitability. Employees act with a sense of ownership, take initiative to problem solve and is committed to the company’s mission, their team and themselves.

United Alloy is supportive and encouraging of our employees, we are able to help make their dreams become a reality. At UA, every employee matters to us. We want everyone to have their own success story in their personal and professional lives. It’s one way that makes us an actively engaged team, inspired to win together.

Equal Opportunity Employer

This employer is required to notify all applicants of their rights pursuant to federal employment laws. For further information, please review the Know Your Rights notice from the Department of Labor.