Sr Design Engineer

Rehlko•Sheboygan, WI

1d•Hybrid

About The Position

Rehlko is seeking a Senior Design Engineer to lead the design and execution of custom enclosures and fuel tank systems for engineered‑to‑order generator solutions. This role is ideal for a mechanical engineer with strong CAD expertise who enjoys owning complex projects from concept through production and collaborating across sales, manufacturing, procurement, and global engineering teams. In this role, you serve as the technical authority for enclosure and fuel tank solutions—balancing customer requirements, manufacturability, cost, and schedule in mission‑critical power applications. The Senior Design Engineer will work closely with cross‑functional partners while remaining deeply hands‑on in design, analysis, and problem resolution.

Requirements

Bachelor’s degree in mechanical engineering (BSME) from an ABET accredited program plus 5+ years of mechanical engineering experience
Hands on Creo CAD modeling experience (required)
Experience designing industrial or engineered products
Ability to independently manage multiple concurrent engineering projects
Strong written and verbal communication skills
Proven ability to collaborate in a cross-functional, global engineering environment
Applicants must be authorized to work in the US without requiring new or transfer visa sponsorship now or in the future.

Nice To Haves

Experience with generator sets, power generation, or industrial engine systems
Knowledge of sheetmetal, welding, and bonding
Experience using Windchill or similar PLM systems
Familiarity with manufacturing processes, fabrication, and assembly
Project leadership or technical lead experience
Exposure to regulatory or standards driven environments

Responsibilities

Lead the mechanical and CAD design of custom enclosures, tanks, and accessories for industrial generator
Own designs from initial customer requirements through engineering release, fabrication, and production support
Create and maintain complex parametric models, assemblies, drawings, and specifications using Creo
Delegate and guide CAD Design Analysts and remote engineering resources
Partner closely with: Sales and Application Engineering to translate customer requirements into engineered solutions
Partner closely with: Platform Lead and Product Management to release product enhancements
Partner closely with: Manufacturing, fabrication, and assembly teams to ensure production readiness
Partner closely with: Purchasing to ensure accurate component selection and on time procurement
Evaluate materials, components, and design approaches to balance performance, quality, manufacturability, and cost
Identify risks, propose solutions, and make data driven engineering decisions
Support and participate in continuous improvement initiatives that streamline custom order and engineering processes
Occasionally interface with customers and global engineering teams
Tackle complex, ambiguous design challenges where requirements evolve and trade offs matter
Diagnose and resolve real production issues involving sheet metal, weldments, fit up, sealing, vibration, and thermal performance
Investigate non conformances and field issues, determine root cause, and implement corrective design actions
Develop practical solutions that work on the shop floor—not just in CAD
Balance speed, cost, quality, and performance while maintaining engineering rigor
Take ownership when issues arise and drive them to resolution, coordinating across engineering, manufacturing, and suppliers