Senior Mechanical Engineer

Job Title: Senior Mechanical Engineer

Location: Hauppauge, NY - On-Site

Position Type: Contract to Hire

Job Summary

We are seeking a highly experienced and innovative Senior Mechanical Engineer to join our dynamic team. This role is focused on the design and development of robust mechanical systems and components for heavy-duty applications intended for harsh and corrosive environments. The ideal candidate is a hands-on, systems-level thinker with a proven track record in designing complex mechanical actuation systems, from concept through to manufacturing. This is not a role for plastic injection molding design; rather, it requires deep expertise in machined components, weldments, and assemblies built to withstand extreme conditions.

Key Responsibilities

• Lead the design and development of complex mechanical systems, custom parts, and assemblies using SolidWorks.
• Perform advanced Finite Element Analysis (FEA) to validate designs for stress, structural integrity, and durability in challenging operational conditions.
• Manage all design data, revisions, and documentation within our Product Data Management (PDM) system.
• Apply expertise in material selection to ensure long-term performance and reliability in corrosive and harsh environments.
• Design and test mechanical actuation systems for heavy-duty applications, providing examples of past successful projects.
• Collaborate closely with electrical and controls engineers to seamlessly integrate motors, sensors, and other electronic components.
• Apply Design for Manufacturability (DFM) principles with a strong understanding of machining, fabrication, and assembly processes.
• Develop detailed manufacturing drawings with proper Geometric Dimensioning and Tolerancing (GD&T).

Required Qualifications & Skills

• Minimum of a Bachelor of Science (BS) in Mechanical Engineering.
• 10+ years of professional mechanical engineering experience is strongly preferred. Significant relevant experience will be considered in the overall assessment of qualifications.
• Expert fluency in SolidWorks for complex 3D modeling and assembly design.
• Expert fluency in a PDM system for data management and revision control.
• Proven, in-depth experience with FEA for structural and stress analysis.
• Demonstrable experience in the design of mechanical actuation systems and machinery for heavy materials.
• Strong background in designing for corrosive environments and understanding of associated material science.
• Experience with material treatment processes such as heat treating, case hardening, and surface coatings for enhanced strength and durability.
• Hands-on familiarity with conventional machining processes.
• A portfolio or ability to present and discuss examples of relevant past design projects.

Preferred Qualifications (A Plus)

• Master of Science (MS) in Mechanical Engineering.
• Professional experience in the Oil and Gas industry.
• Experience conducting Design Failure Mode and Effects Analysis (DFMEA).
• Experience with fluidic analysis (CFD) and designing pressurized chambers or vessels.
• Knowledge of potting, sealing, and gasketing techniques for environmental protection of integrated systems.
• A proven history of working as a "system thinker" in a multidisciplinary team environment.