Mechanical Engineer IV

ACV•Buffalo, NY

About The Position

We are looking for an Engineer IV, Mechanical to lead the design, analysis, and physical integration of complex mechanical systems and hardware onto our next-generation platforms. You will serve as a technical anchor, bridging R&D prototypes with production-ready systems, and taking full ownership of subsystems from concept through to validation and deployment. As a senior member of the team, you will act as a hands-on mentor to junior engineers, establish design standards, and collaborate cross-functionally to deliver highly reliable, high-performance mechanical solutions that can survive demanding real-world environments.

Requirements

Bachelor's Degree (4 years) - Mechanical Engineering, Mechatronics, or equivalent required (Master’s Degree preferred).
8+ year(s) in mechanical design and integration within automotive, aerospace, robotics, heavy machinery, or a high-innovation R&D environment.
Advanced proficiency with 3D CAD platforms (SolidWorks or Onshape preferred) and 2D drafting/geometric dimensioning and tolerancing (GD&T) per ASME Y14.5.
Structural Material Expertise: Deep knowledge of designing with aluminum, steel, and advanced materials, with an emphasis on sheet metal fabrication, welded structures, extrusions, castings, and machined components.
Demonstrated mastery of linear and 2D tolerance stack-up analyses, joint design (bolted, welded, bonded), and component selection (fasteners, seals, materials, coatings).
Strong hands-on experience running structural and modal analyses (ANSYS, Nastran, FEMAP, or equivalent) to validate design integrity under vibration and fatigue conditions.
Proven experience designing IP-sealed enclosures, mounting solutions, and packaging for electromechanical systems in harsh environments.
Direct experience working within a structured product lifecycle management (PLM) environment, including running configuration management, ECO processes, and generating complex BOMs.
Experience managing external fabrication vendors and contract manufacturers from initial Request for Quote (RFQ) through final part delivery.
Comfortable and skilled in a shop or lab environment, using hand tools, basic machining equipment, and diagnostics to support prototype assembly and fit-checks.
Experience in leveraging AI tools to accelerate Mechanical Engineering workflow
Ability to read, write, speak, and understand English.

Nice To Haves

Experience in thermal design, CFD, heat exchangers, or heat sink optimization.
Basic scripting skills in Python, MATLAB, or Go for design automation or data analysis.

Responsibilities

Lead the mechanical engineering efforts for structural design, integration of hardware, and subsystem packaging from initial ideation through to final drawing release.
Own the evolution of early-stage R&D concepts and custom retrofits into scalable, high-reliability, production-ready systems, ensuring designs meet structural, environmental, and safety standards.
Execute finite element analyses (FEA) and first-order hand calculations to validate designs against static, dynamic, modal/vibration, and thermal use cases.
Lead, mentor, and grow the mechanical engineering discipline by establishing best practices, standardizing workflows, conducting deep-dive design reviews, and guiding junior engineers.
Optimize designs for manufacturing, assembly, and serviceability (DFM/DFA/DFS), collaborating closely with manufacturing, procurement, and external vendors.
Pack and physically integrate sensors (cameras, LiDAR, radar, IMUs), compute units, and ancillary equipment, establishing clean routing paths for wire harnesses and cabling within tight mechanical envelopes.
Design sealed, protective enclosures (IP-rated) and thermal solutions (cooling jackets, heat sinks) to safeguard sensitive electronic systems from vibration, dust, and thermal loads.
Participate hands-on in physical bring-up, vehicle integration, and environmental testing campaigns (vibration, shock, thermal-vacuum, etc.), collaborating with validation teams to execute test plans.
Maintain precise Bills of Materials (BOM), assembly documentation, tolerance budgets, and engineering change orders (ECO/DCO) within PDM/PLM systems.
Serve as a key mechanical interface for non-mechanical engineering partners, translating physical constraints and structural trade-offs into clear systems-level decisions.