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About the Role
As Senior Mechanical Engineer, you will be the mechanical owner of how our Bullhorn RMUs, MicroMax interrupters, and DVM instruments look, mount, seal, and last in the field. This is a senior individual-contributor role where you will own new-product mechanical architecture and approve production tooling end-to-end. You will balance industrial design, field installability, and long-term reliability so a customer's first physical impression of our hardware matches its quality.
Responsibilities
- Own mechanical architecture for next-generation IoT hardware across our Bullhorn rectifier RMUs, test-point/AC coupon RMUs, MicroMax interrupters, and field instruments (DVM)
- Design plastic housings, covers, adapters, battery compartments, antenna windows, and user-facing features that protect electronics in outdoor, rectifier-cabinet, and right-of-way environments
- Create 3D concepts and production-intent models that package PCAs, cellular/satellite radios, GPS, batteries, shunts, relays, and connectors into compact, installable products
- Produce complete mechanical design records — CAD models, production prints, GD&T, tolerance stack-ups, BOMs, and revision control — for new products and sustaining changes
- Lead design-for-injection-molding: draft, wall thickness, ribs/bosses, knit lines, gate/ejector strategy, inserts, seals/gaskets, and snap/latch features for industrial, outdoor-rated housings
- Drive tooling from DFM through first-article approval: review mold designs with toolmakers, close dimensional and cosmetic issues, and release production-capable tools as the final mechanical approver on new-product tooling
- Partner with Purchasing, contract manufacturers, and molders to hit cost, lead time, and quality targets, feeding DFM input in early so new products are manufacturable at scale
- Plan and execute mechanical verification and validation for harsh-environment IoT hardware: thermal, humidity, UV, ingress, shock/vibration, drop/abuse, and HALT as needed
- Design for measurement integrity and safety — surge-hardened installs, connector strain relief, creepage/clearance keep-outs, and service access that doesn't compromise the seal
- Support UL/TUV/FCC/safety documentation with mechanical evidence: materials, ratings, labels, and enclosure drawings
- Translate field and Technical Support feedback into durable design changes
- Act as technical owner for new-product mechanical design: review and approve CAD, prints, test plans, and production readiness
- Integrate closely with Electrical, Firmware, Product Management, Operations, and Purchasing so PCA outline, RF keep-outs, thermal paths, and assembly sequence are locked before tooling is cut
- Contribute mechanical deliverables — design records, DFMEA input, prototype plans, and phase-exit evidence — to formal new-product development gates
- Maintain mechanical BOMs, part numbers, and configuration under change control, coordinating with Operations so builds and production transfer aren't blocked by missing prints or tooling
- Use CAD automation, AI-assisted DFM and drawing checks, and reusable design libraries to speed up new-product mechanical work, while retaining ownership of stack-up, material selection, and tooling decisions
- Use simulation (FEA, mold-flow, thermal) to reduce prototype cycles, without substituting analysis for physical ingress, UV, and abuse testing
Requirements
- A bachelor's degree in Mechanical Engineering or equivalent experience, with 7+ years taking electronics-containing products from concept through production tooling
- Demonstrated mastery of plastic injection-molded enclosure design for outdoor or industrial electronics — draft, tooling, seals/gaskets, UV-stable resins — backed by a portfolio of shipped parts
- Hands-on CAD experience (SolidWorks or equivalent) producing production drawings, GD&T, and tolerance analysis, with comfort packaging PCAs, batteries, antennas, and connectors into compact housings
- Experience qualifying hardware for harsh environments: ingress (IP65/NEMA 4X class), temperature, UV, shock/vibration, and practical DFM work with molders and contract manufacturers
- Comfort supporting related processes — sheet metal/aluminum enclosures, 3D-printed prototypes, cable assemblies — used alongside injection-molded parts
- Working knowledge of NPI and design-control practices: design records, ECO/BOM, DFMEA input, and representing mechanical engineering at cross-functional phase gates
- Demonstrated use of CAD automation, AI-assisted DFM/drawing checks, and structured design libraries to increase throughput, without outsourcing engineering judgment
- Experience in outdoor IoT, telemetry/RMU, instrumentation, or other rugged connected devices
- Awareness of antenna/RF keep-out design considerations
- Experience supporting UL/IEC 61010 or comparable safety documentation
- Experience potting electronics
- Experience packaging high-voltage or high-current electronics
- A strong design-for-manufacturability, design-for-testability, or design-for-repairability background
- Eligible to work in the US (visa sponsorship is not provided)
- Must be able to pass a pre-employment background and drug test
Skills
- Mechanical Engineering
- IoT hardware
- Plastic injection-molded enclosure design
- CAD (SolidWorks or equivalent)
- GD&T
- Tolerance analysis
- DFM
- NPI
- Design control
- DFMEA
- CAD automation
- AI-assisted DFM/drawing checks
- Simulation (FEA, mold-flow, thermal)
Location
- US
Work Type
- Full-time
Experience Level
- Senior
- 7+ years
Education Level
- Bachelor's degree in Mechanical Engineering or equivalent experience
Benefits
- Competitive Medical/Dental/Vision Insurance
- Company Provided Life and Disability Insurance
- Paid Family Leave
- Matching 401k
About the Company
- American Innovations helps customers keep their field operations running — our technology and support teams are the front line for the people who rely on our products and services every day.
- We're looking for people who take ownership, communicate clearly, and enjoy solving problems for others.
Equal Opportunity
- American Innovations is an Affirmative Action and Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, or protected veteran status and will not be discriminated against on the basis of disability.