Sr Mechanical Design Engineer

Rochester Sensors LLC•Coppell, TX

16h

About The Position

We are looking for an exceptional Senior Mechanical Design Engineer to architect and develop the mechanical systems for next-generation liquid level sensing technologies used in the world’s most demanding heavy equipment environments. This role is intended for a deep technical engineer who thrives on difficult engineering challenges. The products developed in this position must operate reliably in extreme temperatures, high vibration environments, and harsh industrial conditions where failure is not acceptable. The ideal candidate has previously designed rugged electromechanical products from concept through production, with strong expertise in sensor packaging, vibration-resistant design, sealing strategies, and harsh-environment electronics integration. Sensors developed in Dallas will be deployed globally across construction, agriculture, mining, and commercial vehicle platforms.

Requirements

Bachelor’s or Master’s degree in Mechanical Engineering.
10–15+ years of experience designing rugged industrial or automotive products.
Proven track record developing mechanical systems for electronic sensors or instrumentation.
Strong experience in several of the following areas: 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 working within automotive-grade product development systems, including: APQP, DFMEA / PFMEA, environmental validation testing, and IATF 16949 environments.

Nice To Haves

Mechanical design of liquid level sensors
Experience with guided wave radar probes or instrumentation
Heavy vehicle, construction equipment, or agricultural machinery development
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, not just a CAD designer
Comfortable solving complex physics and materials problems
Experienced designing products that survive in extreme environments
Motivated to create highly reliable sensor systems used worldwide

Responsibilities

Design the mechanical architecture for advanced liquid level sensing systems, including: guided wave radar probes, capacitive sensing structures, and ultrasonic sensor housings.
Develop sensor designs capable of surviving years of operation in extreme duty cycles.
Create mechanical systems that withstand: severe vibration and mechanical shock, extreme temperature ranges (– 40°C to +125°C+), fluid exposure and chemical attack, and dust, contamination, and pressure variations.
Focus on areas including: structural integrity, sealing and environmental protection, electronics packaging, probe and waveguide design, and material selection for durability and corrosion resistance
Perform deep failure analysis and root cause investigations.
Solve problems related to: vibration-induced fatigue, thermal expansion mismatches, fluid interaction with sensing structures, long-term reliability of ruggedized electronics packaging •
Design and perform FEA analysis on designs for rapid failure analysis
Own the mechanical design from concept through production.
Lead prototype development, testing, and design iteration.
Drive design decisions balancing performance, reliability, manufacturability, and cost.
Work within automotive-grade development systems including: APQP, DFMEA / PFMEA, design verification and validation testing
Support development processes aligned with IATF 16949 quality systems.