Senior Mechanical Engineer na Nielsen-Kellerman Co

Description

The Senior Mechanical Engineer will execute all aspects of the mechanical engineering process for both new and existing NK products. Reporting to the Director of Mechanical Engineering, this position will conduct customer needs analysis, ideation, industrial design, 3D mechanical design of enclosures and accessories, prototyping, testing, vendor selection, vendor management, 2D drawing creation, first article approvals, assembly and test process development, fixture creation, process improvement and sustainment. Many NK products feature injection molded  waterproof enclosures with tight tolerances and competing demands of space utilization, size, ruggedness and light weight. The Mechanical Engineer must be highly proficient in SolidWorks and have a track record of turning design concepts into high volume, manufactured products with injection molding plastics and other processes.

Requirements

Essential Functions / Responsibilities 

• Apply extensive and diversified knowledge of mechanical engineering principles and practices to real-world design challenges.
• Design, engineer and support electro-mechanical consumer products using CAD software and other engineering tools.
• Gain understanding of existing NK product lines, materials, processes and technologies.
• Employ Solidworks for CAD development of feature rich components and complex assemblies.
• Leverage parametric, top-down modeling techniques to efficiently develop 3D designs and quickly iterate changes.
• Design for injection molded plastics in high volumes. Utilize best practices of injection molding design through prototyping, material selection, tooling/molding processes, measurement, and assembly.
• Define critical to quality features and specifications through utilization of 3D geometry and 2D technical drawings. Define part and feature tolerancing based on industry standards. 
• Create components and assemblies with design for manufacturing (DFM) and design for assembly (DFA) in mind.
• Define and manage fit and assembly of components including positional features, clearances, press fits, threaded fastening and other techniques.
• Utilize Solidworks tools – clearance check, interference detection, draft analysis and other simulation as needed.
• Develop integrated products with consideration for electrical components including PCBAs, sensors, cables, and batteries. Produce keep out drawings and coordinate with hardware and production engineers.
• Drive communication with domestic and international suppliers to source and manufacture electro-mechanical components that meet defined requirements. On site visits as needed.
• Own revision management of 2D/3D designs through Solidworks PDM, internal ECO processes, and external communication. Generate design packages that capture design intent.
• Evaluate products and components through iterative concept creation, designs and prototypes. 
• Develop testing criteria, strategies, equipment and data acquisition techniques for new and existing NK products. This includes IP67 leak testing, drop testing, environmental testing and other physical performance characteristics.
• Design products with a focus on ergonomics, aesthetics, and user experience. Utilize visuals, renderings, mockups and quick prototypes to review considerations with project teams based on customer use cases.
• Analyze test data and reports to determine if design meets functional, reliability and quality requirements.
• Evaluate first articles for size, tolerances and other aspects of mechanical compliance to documentation.
• Regularly collaborate with cross-functional technical teams including hardware, software, test and manufacturing engineers serving as subject matter experts for mechanical elements of projects.
• Work closely with product and project managers to complete projects on schedule and within cost and performance targets.
• Evaluate and manage process for resolving technical issues that arise during the product development lifecycle.
• Partner with production engineers and technicians to ensure proper assembly and functionality.
• Direct, coordinate, or fabricate prototype product sample builds.
• Document product designs through internal materials and procurement teams. 
• Produce product documentation that identifies critical product dimensional, assembly and performance requirements for vendors and line operators.
• Produce complete and accurately costed Bills of Materials for mechanical assemblies.
• Utilize business systems in a high volume, production environment including ERP and ECO.

Required Competencies and Personal Qualities 

• Positive attitude and ability to work with diverse teams of varying backgrounds and skillsets.
• Desire to continuously learn new skills, products and knowledge, as well as develop professionally.
• Able to work independently on major projects and/or several projects of moderate scope with complex features. 
• Capable of working on multiple projects at once. Comfortable with ambiguity or fluidity on projects.
• Take initiative, working independently or within a group without direct supervision.
• Proven as an innovative designer and problem solver.
• Ability to take ownership of tasks and projects from start to finish. 
• Ability to iterate designs and take multiple solution approaches simultaneously. Perseverance through project unknowns, challenges and failures. 
• Ability to work collaboratively with team members, including other design and manufacturing professionals, line workers and vendors.
• Ability to conduct internet research and use the full Microsoft Office suite to accomplish job responsibilities.
• Both willing and able to learn new things while also having good judgement to recognize when you need to seek outside advice and assistance
• Excellent time-management, prioritization and task completion.
• Good communication and interpersonal skills.
• Excellent analytical and problem-solving skills.

Education and Experience

• Bachelor’s degree in Mechanical Engineering
• 7+ years of experience of developing products for high volume manufacturing
• Expert in design of plastic injection molded components with DFA and DFM in mind.
• Experience driving communication with suppliers throughout product development process. 
• Experienced in revision control and 100% design definition to capture design intent and control quality.
• Highly proficient in Solidworks: 3D design with top-down modeling, parametric techniques. 2D drawings with appropriate tolerancing and quality controls based .on industry standards. Familiar with Boolean and surface modeling as well as evaluation tools.
• Experience designing and validating robust electromechanical consumer products for IP67 leak testing, drop testing, ESD, environmental testing, and other performance or regulatory requirements.
• Industrial design experience including ergonomics, aesthetics, textures, material selection. Ability to generate concepts through drawings, renderings, 3D models and prototypes. 
• Knowledge of manufacturing processes including plastics injection molding, stamping, forming, machining, laser cutting, 3D printing and additive manufacturing and material knowledge of plastics, metals, gaskets, seals, adhesives and glues. 
• Experience working with assembly processes and equipment including fixtures, jigs, presses, fasteners and glues. 
• Experience and/or training in lean manufacturing principles.
• Experience working with hand tools and in a machine shop.

Supervisory Responsibility 

This position does not have direct supervisory responsibilities. 

Work Environment and Physical Demands

Climate-controlled indoor office with attached manufacturing facility. May be required to stoop, kneel, crouch or crawl, climb or balance. Must be able to lift and/or move up to 20 pounds. Dogs may be present in office. 

Training 

Most training is on-the-job but formal education and training may be provided where appropriate. 

Work Location & Hours 

Hybrid work environment that can accommodate remote work with some regular need to be in the office (likely 2-3x per week). NK’s facilities are located in Boothwyn, PA. Occasional travel may be required for training, evaluation of capital test equipment, or working with consulting engineers.  

Pay Rate 

This is a salaried position. Pay rate commensurate with qualifications and experience as well as company size. Annual bonus based on company and individual performance ranges averages 2% to 4% of compensation. 

Benefits

• Fully paid employee benefits include medical, dental, vision, disability and life insurance.
• Voluntary benefits include family medical, life insurance, critical care insurance, FSA dependent care and pet insurance
• Paid Maternity/Paternity Leave 
• HSA with employer contribution 
• 401k with employer match to 5% after 90 days. 
• 9 paid holidays, and flexible PTO

All benefits are subject to a benefit waiting period of 60 to 90 days.

Work Authorization/Security Clearance 

Must be eligible to work in the US without sponsorship. Security clearance is not required. 

Equal Opportunity Employer 

NK is an equal opportunity employer. NK conducts all employment-related activities in full compliance with all applicable Federal and State laws and without regard to an individual’s age, color, gender, disability, marital status, national origin, citizenship, race, religion, sexual orientation, veteran status or other legally protected categories. No person will be discriminated against in hiring or in any other aspect of their employment including training, transfer, promotion, compensation, benefits and all other aspects of employment. Reasonable accommodation will be made to enable individuals with disabilities to perform the essential functions of this position.

About NK 

Nielsen-Kellerman is the parent company for eight brands focused on helping people succeed in their profession or passion by providing mission-critical measurements, information, insight, and guidance whenever and wherever needed. Ambient Weather, Kestrel Weather, KestrelMet, RainWise, Kestrel Ballistics, MagnetoSpeed, Blue Ocean Megaphones and NK Sports are each recognized as the preeminent products for their applications from meteorology to military, firefighting to farming and rowing to research. Our products ARE us - we design them, build them, sell them, and passionately stand behind them. 

NK has been in business for over four decades and is still growing stronger. Working here offers excellent opportunities for personal and professional development as well as the fun and satisfaction of being part of a successful American business. NK is a Lean enterprise committed to American manufacturing and continuous improvement of our design, production, administrative and sales processes.

NK's home office is located in Boothwyn, PA, about 30 minutes southwest of Philadelphia and our Ambient Weather brand operates primarily from Chandler, AZ in the Phoenix suburbs. NK's work environment is informal and high-energy, and our employees' quality of life is important to us. NK is proud to have been named a Philly Top Workplace eight out of the last ten years including 2025.