Staff R&D Mechanical Engineer

Dahl Consulting; Houston (TX); Hybrid; USD 135,000 - 140,000; Full time

Job summary

Dahl Consulting is seeking a Staff R&D Mechanical Engineer in Houston, TX. The role combines technical leadership in mechanical design and new product development for electrical infrastructure applications, with hybrid work (onsite 4 days a week and one work-from-home day).

Up to 10% travel is expected domestically. You will guide cross-functional teams through concept to commercialization, influence technology roadmaps, and uphold design standards to ensure reliability and manufacturability of

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• 8+ years of mechanical design experience.
• Strong experience with non-metallic materials and components.
• Knowledge of polymer/non-metallic material behavior (thermoformed components, elastomeric seals, gaskets, fiber-reinforced).

Responsibilities

• Lead development of new products from concept through validation and commercialization.
• Collaborate with global cross-functional teams (engineering, manufacturing, quality, compliance, product management).
• Drive validation plans, testing, and certification activities.
• Define best practices, design standards, and manufacturability improvements.

Skills

Mechanical design

NPI experience

FEA

FMEA

Non-metallic materials

Product development

Education

Bachelor's degree in Mechanical Engineering

Job description

Title: Staff R&D Mechanical Engineer

Location: Houston, TX (Hybrid | Onsite 4 days per week, can pick work from home day)

Job Type: Permanent

Compensation: $135,000 - $140,000 plus 5% bonus Annually

Industry: Electrical Manufacturing

About the Role

Our client, a global leader in electrical connection, protection, and infrastructure solutions, is seeking a Staff R&D Mechanical Engineer to join their product development team in Houston, Texas. This organization designs innovative products that help protect critical equipment, facilities, and industrial processes across a wide range of industries worldwide. In this senior-level engineering role, you will lead the development of new products and technologies with a strong emphasis on mechanical design, non-metallic materials, and product innovation. You will collaborate with cross-functional teams throughout the product development lifecycle, helping drive projects from concept through validation, certification, and commercialization. This position offers the opportunity to influence product strategy, support technology roadmaps, and contribute to a culture focused on innovation and continuous improvement.

Travel: Up to 10% domestic travel.

Job Description

As a Staff R&D Mechanical Engineer, you will play a critical role in developing innovative products that support critical electrical infrastructure and industrial applications. This position combines technical leadership, hands‑on engineering, and cross-functional collaboration to bring new products from concept to commercialization. Working closely with global engineering, manufacturing, quality, compliance, and product management teams, you will drive product innovation, validate performance, optimize manufacturability, and help shape future technology strategies that enhance product reliability, quality, and customer value. Participate in global product development teams, working closely with manufacturing engineering, supply chain, quality, compliance, and product management stakeholders. Lead and support prototype development, testing activities, and external certification efforts, including hands‑on engineering support when necessary. Guide engineering simulations and analyses, including FEA and FMEA, to validate product performance, reliability, and design effectiveness. Define and coordinate validation plans, laboratory testing, and performance evaluations. Collaborate with internal and external fabrication partners to develop practical, scalable, and cost-effective manufacturing processes. Design, develop, and improve both new and existing products in alignment with business and product development strategies. Establish engineering best practices and design standards that optimize performance, quality, reliability, manufacturability, and cost. Support continuous improvement initiatives and contribute to technology development across multiple teams and functions. Serve as a subject matter expert for product technologies, supporting product portfolio planning and long‑term technology roadmaps. Ensure compliance with applicable industry standards, certifications, and regulatory requirements.

Qualifications Required

• Bachelor's degree in Mechanical Engineering, a related engineering discipline, or equivalent combination of education and experience.
• 8+ years of mechanical design experience, preferably supporting new product introduction (NPI) and product development initiatives.
• Strong experience working with non-metallic materials and components.
• Demonstrated knowledge of polymer and non-metallic material behavior, including: Thermoformed components, Elastomeric seals and gaskets, Fiber-reinforced and