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KORE1 · 1 week ago

Senior / Principal Mechanical Design Engineer: End-to-End Electro-Mechanical Development (Med Device or Military / Defense)

Gray, ME

Full-time

Onsite

Senior Level, Lead/Staff

$90K/yr - $135K/yr

7+ years exp

KORE1 is a nationwide provider of staffing and recruiting solutions, currently seeking a Senior / Principal Mechanical Design Engineer for end-to-end electro-mechanical development in medical devices and military/defense sectors. This role requires ownership of mechanical design processes, collaboration with cross-functional teams, and hands-on support for product development from concept to production.

Bookkeeping and PayrollConsultingDeliveryHuman ResourcesInformation TechnologyRecruitingStaffing Agency

Growth Opportunities

No H1B

U.S. Citizen Only

Hiring Manager

Jennifer (Burdick) Thomas (L.I.O.N. with extensive network)

Responsibilities

Own full lifecycle mechanical design from concept development through beta, verification/validation, and production support

Perform hands-on SolidWorks CAD design at part, assembly, and system levels, including detailed drawings and documentation

Design assemblies and components with responsibility for part-level and system-level tolerance analysis, fault analysis, and fit/function validation

Lead electro-mechanical integration, including mechanical packaging of electronics, integrated PCBs, and collaboration with Electrical Engineering on cable and harness drawings

Perform tolerance stack-up analysis and maintain documentation to support IP, design justification, and downstream manufacturing

Conduct basic stress analysis as a requirement, with broader FEA for strength expected; thermal analysis is a plus and flow analysis is optional

Support designs involving fluidic components, with emphasis on mechanical and thermal considerations rather than fluidic modeling

Provide hands-on beta and production floor support, including troubleshooting, root cause analysis, and rapid design iteration

Design and support custom test fixtures and test PCs, including fixtures for ablation machines and other medical device test systems

Contribute to redesigns driven by component obsolescence, including re-packaging and updates to small medical and veterinary devices

Support development across a diverse product mix, including medical devices (primary), automotive drive-by-wire retrofit systems, industrial programs, and custom customer solutions

Participate in frequent customer-facing activities, including weekly (or more frequent) virtual meetings, PowerPoint-based technical design reviews, and rare onsite visits

Actively discuss and influence project schedules, timelines, effort estimates, and tradeoffs in partnership with Project Managers

Apply DFM, DFMEA, usability, reliability, and verification & validation practices throughout the design lifecycle

Select appropriate materials and manufacturing processes with high autonomy, including machined parts, sheet metal, injection-molded plastics (design only, not tooling), castings, and extrusions

Collaborate with Process Engineering on fixtures and tooling, recognizing this is a supporting responsibility rather than the primary focus at the Principal level

Ensure BOM accuracy and design documentation quality, including review and approval of MCRs, part numbers, and related process documentation

Utilize in-house prototyping and shop resources as needed, including milling, expanding lathe capability, band saws, grinders, and multiple 3D printing platforms

Success in this role is measured by meeting deadlines, delivering designs that fit and function correctly, and executing projects on time and under budget, enabling smooth progression from concept to beta and into production

Serve as mechanical lead on complex, multi-disciplinary customer programs

Provide deep technical judgment, decision-making authority, and customer credibility on high-impact projects

Identify technical risks, alternatives, and design tradeoffs early and drive resolution

Review, guide, and provide oversight on work performed by junior and senior engineers (formal mentorship not required)

Partner with Project Managers on quoting, scoping, and long-range technical planning

Act as a subject matter expert in mechanical and electro-mechanical design

Contribute to improvement of mechanical design processes, tools, and standards during a period of team growth and transition

Qualification

Mechanical EngineeringSolidWorksElectro-mechanical systemsTolerance stack-up analysisBasic stress analysisGD&TInjection-molded plasticsThermal analysisCommunication skillsProject management

Required

Bachelor's degree in Mechanical Engineering or a related engineering discipline, or equivalent practical experience

Strong hands-on mechanical design depth, particularly in medical device and regulated product development environments; will consider military/defense industry experience instead of medical device

Senior Mechanical Design Engineer: Typically 7+ years of relevant mechanical design experience

Principal Mechanical Design Engineer: Typically 15+ years of relevant mechanical design experience with demonstrated technical leadership and customer credibility

Professional experience using SolidWorks for 3D models, assemblies, and drawings

Experience with electro-mechanical systems, including PCB integration and collaboration on cable and harness drawings

Demonstrated expertise in tolerance stack-up analysis, GD&T, and detailed design documentation

Required experience performing basic stress analysis; broader FEA for strength required at higher complexity levels

Experience designing with injection-molded plastics (design only), machined components, sheet metal, castings, and extrusions

Experience supporting beta builds and production floor activities in a hands-on capacity

Ability to manage multiple concurrent customer programs and operate with a high degree of autonomy

Strong written and verbal communication skills, including the ability to lead customer-facing technical design reviews using presentation tools such as PowerPoint