Mechanical Design Engineer II

Key Responsibilities: Electro-Mechanical & Thermal Packaging• 3D CAD & Enclosure Design: Lead mechanical CAD development (Solid Works) for rugged LED light housings, bezels, lenses, and mounting hardware.• Thermal & Environmental Shielding: Design high-performance heat sinks and thermal dissipation pathways for high-output LED arrays while sealing housings against dust and high-pressure washing (IP68/IP69K).• PCB & Optical Integration: Work closely with electrical engineers to integrate custom PCBs, wiring harnesses, lenses, and reflectors into tight mechanical footprints. Materials, Prototyping & DFM• Material Selection: Select optimal metals, engineered plastics, thermal interfaces, gaskets, and coatings to maximize strength, weight savings, and environmental resistance.• Rapid Prototyping & Testing: Build, assemble, and bench-test functional prototypes using 3D printing, CNC machining, and lab environmental testing.• Manufacturing Optimization: Design for Manufacturability/Assembly (DFM/DFA) across die-cast aluminum, injection molding, and sheet metal processes. OEM Execution & Quality Standards• OEM Technical Specs: Interpret, author, and validate mechanical drawing standards, tolerance stacks (GD&T), and technical specs for OEM clients.• Automotive Compliance: Ensure all mechanical assemblies comply with SAE/DOT standards, vibration/shock requirements, and thermal shock cycles.• Production Support: Partner with manufacturing teams and vendors to resolve tooling, tolerance, or assembly issues during initial production ramps. Qualifications & Skill Set• Education & Experience: Bachelor’s degree in Mechanical Engineering (BSME) or related field with 3–6 years of hands-on mechanical product design experience (preferably in automotive, lighting, or rugged electronics).• Solid CAD & GD&T Skills: Strong proficiency in 3D CAD design (Solid Works) and practical application of GD&T (ASME Y14.5).• Electro-Mechanical Design: Proven experience packaging electronics, thermal interfaces, optical optics, or die-cast aluminum/injection-molded components.• OEM Spec Mastery: Experience interpreting, creating, and validating engineering specifications and drawings for OEM automotive applications.• Thermal & FEA Analysis: Fundamental knowledge of thermal simulation (CFD) and structural analysis (FEA) to validate designs prior to prototyping. Preferred / Bonus Points• Off-Road & Automotive Passion: Active involvement in the automotive or off-road community (overlanding, rock crawling, motorsports) is a huge plus—you understand the real-world abuse our gear faces.• Optical Packaging: Familiarity with secondary optical design, reflector geometry, or polycarbonate lens molding.• Supplier Coordination: Experience working with overseas or domestic tooling vendors and machine shops.