Senior Mechanical Design Engineer

Leonardo Electronics US Inc•Tucson, AZ

21d•Onsite

About The Position

Leonardo is seeking a Senior Mechanical Design Engineer to join their team and lead the development of next-generation diode laser systems. This role involves approximately 50% hands-on development in cleanroom and laboratory facilities, transforming concepts into reality through design, prototype development, and testing. The position is highly collaborative, requiring engagement with customers, internal teams, and external partners. The Senior Mechanical Design Engineer will also mentor junior engineers and guide project priorities.

Requirements

A Bachelor of Science degree in Mechanical Engineering from an ABET accredited institution.
A minimum of 6 years of impactful experience in a related engineering field, demonstrating a clear history of increasing responsibility and independent thinking, culminating in the successful design and implementation of complex products.
Proven expertise with hands-on development and prototype builds, including the ability to thrive in a cleanroom environment up to 50% of the time.
A desire to own products from concept to completion, embracing the full lifecycle of innovation.
Exceptional understanding of thermal design, particularly with heatsinks and heat exchangers, across various fluids and materials.
Experience in designing mm to micron level components, assemblies, and tooling.
Familiarity with technologies for manufacturing precision mechanical components (metals, ceramics, glass) in low to medium volumes.
A practical and applied knowledge of ANSI Y14.5-2018 from creating your own 2D drawings.

Nice To Haves

SolidWorks CSWP highly desired.
ANSYS (Mechanical & Fluent expertise a significant plus).
Prior experience with laser systems (diode arrays, solid-state, fiber) and some knowledge of optics is highly preferred.
Experience with composite metals for thermal interfaces and metal additive manufacturing in a production environment.

Responsibilities

Lead the design and rigorous analysis of complex mechanical components and assemblies, including high-performance heatsinks and heat exchangers, precision optical assemblies, medical, military, commercial, and scientific grade assemblies, opto-mechanical and electro-mechanical assemblies, and advanced direct diode laser sources, fiber coupled laser systems, and supporting tooling and test system design.
Tackle engineering challenges with sound engineering principles and creative thinking.
Perform 3D and 2D CAD design and detailing using SolidWorks, adhering to ANSI Y14.5M standards and GD&T.
Utilize ANSYS and other analytical tools for design validation.
Guide junior engineers and technicians, driving project success and fostering technical excellence.
Collaborate with Program Managers to maintain project scope and budget.
Ensure successful product development transfer to production with Product Engineers.
Present complex design reviews to internal stakeholders and external customers.
Engage in prototype assembly and debugging, working with a multidisciplinary team.
Develop advanced solder reflow and hierarchy techniques, including micro component assembly tooling.
Develop pump and cooling systems for complex coolant systems.
Build and verify laser testing equipment for prototype development and production implementation.
Construct and validate assembly tooling for precision micro-component and micro-optics assembly.
Spearhead research, development, and implementation of new mechanical design technologies to enhance power output, reliability, efficiency, SWaP, and robustness of laser arrays and systems.