Senior Mechanical Engineer

DISA Technologies•Casper, WY

About The Position

The Senior Mechanical Engineer is a technical leader responsible for the architecture, integrity, and performance of DISA’s HPSA mechanical systems from concept through commercial deployment. This role provides subject-matter expertise in high-wear, high-pressure process equipment and leads mechanical design strategy, scale-up, and reliability engineering initiatives. The Senior Mechanical Engineer will serve as a mentor to junior engineers, drive cross-functional alignment, and ensure mechanical systems meet performance, safety, manufacturability, and cost targets. This position plays a critical role in advancing DISA’s commercialization roadmap, ensuring robust, field-ready systems that perform reliably in demanding mining and remediation environments. The successful candidate will thrive in a dynamic start-up environment, wearing multiple hats and contributing to many areas of business development.

Requirements

Advanced knowledge of mechanical design principles, materials science, wear mechanisms, and high-pressure systems.
Extensive experience in structural analysis, mechanical system troubleshooting, and field diagnostics.
Demonstrated ability to lead complex engineering projects from concept through deployment.
Strong background in reliability engineering, failure analysis, and continuous improvement methodologies.
Proficiency in engineering software (e.g., SolidWorks, AutoCAD, MATLAB, Minitab, Aspen, or similar tools).
Strong analytical and problem-solving capabilities with a data-driven decision-making approach.
Proven ability to manage complex, multi-stakeholder projects.
Communicate clearly and professionally, both verbally and in writing, to collaborate with colleagues, stakeholders, and clients.
Organize and prioritize tasks to meet deadlines while managing multiple projects.
Collaborate effectively as part of a team, supporting shared goals and fostering positive relationships.
Adapt to dynamic environments and identify solutions to challenges with flexibility and problem-solving skills.
Maintain professionalism with high attention to detail, reliability, accountability, and accuracy in all work deliverables.
Uphold and demonstrate DISA’s Values of Dedication, Innovation, Sustainability, and Accelerate Change.
Ability to follow safety protocols and maintain compliance with OSHA/MSHA and company safety standards.
Be a valid U.S. citizen or legally authorized to work in the United States.
Possess a valid driver’s license with a clean driving record.
Must be able to sit and/ or stand for extended periods of time.
Must be able to lift up to 50 lbs. occasionally.
Must be able to interact with people and technology while either standing or sitting.
To best service our customers, all employees must be able to communicate face-to-face and on the phone with or without reasonable accommodation.
Ability to travel up to 25%.
Must be able to perform repetitive tasks such as typing.
Bachelor’s degree in Mechanical Engineering required
Minimum of 10 years of progressive experience in mechanical design, product development, and field deployment, preferably in mining, oilfield services, process equipment, heavy industrial systems, or related industries.

Nice To Haves

Master’s degree preferred.
Professional Engineer (PE) license preferred but not required.
Demonstrated experience leading engineering projects, mentoring team members, and managing technical deliverables across multiple concurrent initiatives.

Responsibilities

Own mechanical system design for HPSA units, process skids, and related equipment from concept through commercialization.
Define design standards, specifications, and engineering best practices for mechanical systems.
Lead structural, thermal, fatigue, and wear analyses to validate system integrity and safety.
Serve as the mechanical subject-matter expert for high-pressure and high-wear process applications.
Approve and review detailed 3D models and engineering drawings to ensure quality, compliance, and manufacturability.
Lead R&D initiatives focused on product optimization, durability, and field performance.
Drive scale-up efforts from prototype systems to commercial production units.
Apply advanced Design for Manufacturing (DFM) and Design for Assembly (DFA) principles to reduce cost, complexity, and lead times.
Develop validation plans, oversee testing protocols, and interpret data to guide iterative improvements.
Collaborate with supply chain and manufacturing partners to ensure production readiness and quality control.
Establish reliability engineering frameworks to reduce downtime and extend equipment life.
Lead root cause analyses for component or system failures and implement corrective and preventive actions (CAPA).
Conduct wear testing, materials selection analysis, and performance benchmarking.
Develop and maintain mechanical performance KPIs to support commercialization and customer satisfaction.
Collaborate with process, electrical, controls, and field operations teams to ensure integrated system performance.
Support customer site visits, commissioning efforts, and technical presentations.
Interface with external consultants, fabrication partners, and strategic collaborators.
Contribute to technical documentation, IP development, and patent support as needed.
Mentor and provide technical guidance to junior engineers and technical staff.
Lead design reviews and engineering gate processes.
Support workforce development initiatives by contributing to training materials and engineering standards.
Promote a culture of safety, accountability, innovation, and operational excellence.
Abide by all policies and procedures established by DISA.
Attend and participate in all required safety trainings.
Assist with any task required by the direct supervisor.