Sr Mechanical Design Engineer

Rochester Sensors LLC•Coppell, TX

8h•Onsite

About The Position

Rochester Sensors is seeking a Senior Mechanical Design Engineer to architect and develop mechanical systems for next-generation liquid-level sensing technologies used in demanding heavy-equipment environments. The role focuses on rugged electromechanical products that must operate reliably under extreme temperatures, high vibration, and harsh industrial conditions. The engineer will own designs from concept through production, including sensor packaging, vibration-resistant design, sealing strategies, and integration of electronics for harsh environments. Products developed in Dallas will be deployed globally across construction, agriculture, mining, and commercial vehicle platforms. The position is not remote and must be based in the Dallas–Fort Worth area. Up to 10% travel may be required. The work includes mechanical architecture for guided-wave radar probes, capacitive sensing structures, and ultrasonic sensor housings. Designs must withstand severe vibration and mechanical shock, temperatures from –40°C to +125°C or higher, fluid exposure and chemical attack, and dust, contamination, and pressure variations. The engineer will perform failure analysis, root-cause investigations, and FEA, and will lead prototype development, testing, and design iterations. Development processes include APQP, DFMEA/PFMEA, design verification and validation, and alignment with IATF 16949 quality systems. The physical demands may include prolonged walking; occasional bending, climbing, rotating, squatting, reaching, kneeling, and stooping; lifting up to 40 pounds; and periods of computer use. Employees may be frequently exposed to heat and cold, heights, gases, vibration, dust, chemicals, odors, dampness, fumes, and noise. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Requirements

Bachelor’s or master’s degree in Mechanical Engineering.
At least 5 years of experience designing rugged industrial or automotive products.
Proven track record developing mechanical systems for electronic sensors or instrumentation.
Strong experience in several areas such as harsh-environment product design, ruggedized electronics packaging, vibration- and fatigue-resistant mechanical systems, fluid-contact sensor structures, sealing systems and ingress protection, and materials engineering for extreme environments.
Advanced experience with 3D CAD systems.
Experience using FEA tools for structural, vibration, and thermal analysis.
Experience with automotive-grade product development systems, including APQP, DFMEA/PFMEA, environmental validation testing, and IATF 16949 environments.
Must be located in the Dallas–Fort Worth area; this is not a remote position.

Nice To Haves

Mechanical design of liquid-level sensors.
Experience with guided-wave radar probes or instrumentation.
Experience developing heavy vehicles, construction equipment, or agricultural machinery.
EMI/EMC-conscious electronics packaging.
Design for IP67/IP69K environmental protection.
Experience designing products for long service life in high-vibration environments.
A hands-on mechanical architect, rather than only a CAD designer.
Comfort solving complex physics and materials problems.
Experience designing products that survive in extreme environments.
Motivation to create highly reliable sensor systems used worldwide.

Responsibilities

Design mechanical architectures for liquid-level sensing systems, including guided-wave radar probes, capacitive sensing structures, and ultrasonic sensor housings.
Develop sensor designs intended to withstand years of operation in extreme duty cycles.
Design for severe vibration and mechanical shock, extreme temperatures, fluid exposure and chemical attack, dust, contamination, and pressure variations.
Address structural integrity, sealing and environmental protection, electronics packaging, probe and waveguide design, and durable, corrosion-resistant material selection.
Perform failure analysis and root-cause investigations, including investigation of vibration-induced fatigue, thermal expansion mismatches, fluid interactions with sensing structures, and long-term reliability of ruggedized electronics packaging.
Design and perform FEA for rapid failure analysis.
Own mechanical design from concept through production.
Lead prototype development, testing, and design iteration.
Make design decisions that balance performance, reliability, manufacturability, and cost.
Work within automotive-grade development systems, including APQP, DFMEA/PFMEA, and design verification and validation testing.
Support development processes aligned with IATF 16949 quality systems.