Lead Mechanical Engineer -- Sheet Metal & Costing

Job Description

Job DescriptionJoin Us to Engineer What Gets Built

We design and manufacture custom and semi-custom sheet metal enclosures and electromechanical assemblies. In this role, you will own both the engineering and the economics—turning requirements into manufacturable designs and building accurate quotes that keep promises to customers and our shop.

Impact AreasDesign & Analysis

• Own SolidWorks models for enclosures, chassis, panels, and brackets.
• Engineer complete electromechanical assemblies: structural components, hardware selection, wiring harness routing, mounting features.
• Deliver production drawings with ASME Y14.5 GD&T, bend allowances, materials, and finishes.
• Engineer for DFM/DFA across laser cutting, turret punching, press brake forming, MIG/TIG/spot welding, PEM hardware, and finishing (powder, plating, anodize).
• Optimize for cost, mass, thermal paths, and assembly efficiency.
• Execute tolerance stack-ups; perform structural calculations and targeted FEA for load-bearing situations.

Quoting & Value

• Build cost estimates from first principles: material, fabrication/finishing time, purchased components.
• Create formal quotations with BOMs, labor hour models, process routing, and pricing.
• Align assumptions with Manufacturing and Purchasing; run make-vs-buy evaluations.
• Lead value engineering initiatives to reduce cost while preserving function and quality.

Collaboration

• Interface with customers and Sales to clarify environments, performance targets, and budgets.
• Run internal and customer-facing design reviews.
• Partner with Manufacturing Engineering to match designs to in-house capabilities/tooling.
• Coordinate with Quality on inspection plans and acceptance criteria.
• Support prototypes and first article inspections; assist production and field issue resolution.

Standards & Data Integrity

• Maintain CAD, drawings, and ECOs within PLM/PDM.
• Comply with UL, NEMA, IP ratings, and customer standards.
• Develop reusable design guides and component libraries; archive decisions, calcs, and test evidence.

QualificationsRequired

• BS in Mechanical Engineering (or related).
• 5–7 years in mechanical design with strong sheet metal focus.
• Proficiency in 3D CAD (SolidWorks preferred) and 2D detailing.
• Process fluency: laser cutting, turret punching, press brake forming, MIG/TIG/spot welding, PEM fasteners, powder/plating/anodizing.
• Material knowledge: steel alloys, aluminum, stainless.
• GD&T per ASME Y14.5.
• Strong analytical skills, attention to detail, and excellent written/verbal communication.

Preferred

• Cost estimating/quoting exposure—or proven cost-aware design decisions (DFM, vendor tradeoffs, make-vs-buy); readiness to grow this scope.
• FEA tools: SolidWorks Simulation, ANSYS, or similar.
• Thermal strategies for electronics enclosures.
• EMI/RFI shielding and grounding practices.
• NEMA 1/12/4/4X and IP rating experience.
• High-volume production and assembly automation background.
• Electrical/electronic packaging and cable management familiarity.
• PLM/PDM experience (Windchill, Teamcenter, etc.).
• Standards knowledge: UL, CSA, CE marking.

Success Profile

• Analytical and cost-conscious decision maker.
• Organized multitasker who manages several projects simultaneously.
• Customer-focused translator of requirements into practical designs.
• Collaborative partner to Manufacturing, Purchasing, and Sales.
• Self-motivated finisher who thrives in fast-changing environments.

Toolstack

• CAD: SolidWorks (primary), AutoCAD.
• Analysis: SolidWorks Simulation or similar FEA.
• PLM/PDM for revision control and ECOs.
• ERP for BOM and cost integration.
• MS Office: Excel, Word, PowerPoint.

Work Setting & Travel

Office-based at our Sterling, MA headquarters with frequent time on the manufacturing floor for prototypes, producibility checks, and process improvements. Travel to customers/suppliers: approximately 5–10%.

Benefits & Perks

• See designs manufactured in a state-of-the-art fabrication facility.
• Close collaboration with seasoned manufacturing experts.
• Diverse projects across industries and applications.
• Comprehensive benefits: medical, dental, vision; 401(k) with company match; holidays and paid time off; eligibility for Long Term Investment Plan (LTIP).

Core Proficiencies

• Project Management
• CAD Software
• Design for Manufacturability (DFM)
• Design for Assembly (DFA)
• Mechanical Design & Engineering
• Product Design Experience
• Sheet Metal Design & Fabrication