Mechanical Engineer 3, Solar Roof R&D

GAF • Georgetown, TX

13d

About The Position

GAF Energy is seeking an experienced Mechanical Engineer 3 to join our R&D team. You will play a critical role in supporting released products, and in designing, testing, and integrating our next-generation building-integrated photovoltaic (BIPV) roof systems. This exciting role will report to the Sr. Director, System Integration, and will work in a small, agile R&D team, collaborating with Manufacturing, Reliability, and Product Management. The role features significant opportunity for growth, so you'll need to be adept at mentoring others and communicating cross-functionally. Your work will be crucial to ensuring our mechanical systems are robust, manufacturable, cost-effective, and seamlessly integrated into a world-class product. The ideal candidate must have a passion for renewable energy, deep expertise in mechanical design and system integration, and thrive in a fast-paced, hands-on R&D environment. With your outstanding technical acumen and attention to detail, you can help us protect what matters most.

Requirements

• Bachelor’s Degree Mechanical Engineering or a related technical field. required
• 5+ years of experience in a product development, mechanical or electromechanical design role.
• Experience with PV module components, materials, and fabrication techniques.
• Expert proficiency in 3D CAD software (SolidWorks including PDM Vault preferred).
• Strong experience in designing for high-volume manufacturing processes (e.g., injection molding, extrusion, sheet metal stamping, die casting).
• Demonstrated ability to apply FEA, FMEA, and other analytical methods to solve complex design problems.
• A "can-do" attitude and a hands-on passion for prototyping (3D printing, machining, etc.) and laboratory testing.
• Strong, fundamentals-based problem-solving skills and an aptitude for learning systems quickly.
• Proven track record of innovation and creative problem-solving.
• Excellent project management and organizational skills, with the ability to manage multiple tasks and drive projects to completion.
• Strong ability to communicate clearly and effectively with internal and external cross-functional teams.
• Willingness and ability to spend a significant portion of the day in an R&D lab, production floor, or on test roof sites.

Nice To Haves

• Master’s Degree in Mechanical Engineering.
• Experience in the roofing, residential construction, or building materials industry.
• Knowledge of building codes and product certification standards (e.g., UL, ASTM, ICC-ES).
• Experience with ANSYS.
• Experience with composite materials
• Experience with factory automation, factory metrology, and AI-based machine learning techniques to support process control.
• Experience with configuration management tools (Arena preferred).

Responsibilities

• Lead the mechanical design, analysis, and validation of components and subsystems for BIPV roofing products from concept to production, including mounting, flashing, wire management, enclosures, and thermal performance.
• Apply mechanical engineering principles to the design, integration, and testing of PV module components (e.g., solar cells, encapsulants, glass, backsheets, junction boxes) within the BIPV system.
• Create and maintain detailed 3D CAD models (SolidWorks), assemblies, manufacturing drawings, and BOM’s
• Perform tolerance analysis, GD&T, and Design for Manufacturability/Assembly (DFM/DFA) to ensure robust and cost-effective designs.
• Develop and execute comprehensive validation test plans (DVTs) for mechanical and electromechanical systems, including structural, environmental, and reliability testing.
• Build and test functional prototypes in laboratory and real-world environments to validate designs and iterate quickly.
• Collaborate with manufacturing engineering to scale designs from prototype to high-volume production, including the design of assembly jigs and fixtures.
• Manage relationships with external vendors and partners for component sourcing, fabrication, and co-development.
• Create and present technical documentation, design reviews, and test reports to cross-functional and executive stakeholders.

Benefits

• We offer a wide range of health insurance options that include medical, dental, and vision for you and your family.
• Our Family-Building benefits support the many different journeys to fertility and parenthood.
• Our robust 401K plan includes an employer match contribution with your pre-tax and/or Roth contributions.
• Other exciting programs and perks are available to help employees achieve work-life balance, including (but not limited to) a wellness program, free financial coaching, a referral program, and product rebates when purchased for an employee’s primary residence.
• Professional growth and development are very important to us! We offer internal training programs and courses, as well as a generous tuition reimbursement program.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 51-100 employees