Principal Product Design Engineer

We are seeking a Principal Product Design Engineer to serve as a technical authority in the design and development of rugged electro-mechanical sensors for industrial fluid sensing and control applications. This role combines hands-on design with engineering mastery of mechanical fundamentals to translate complex requirements into manufacturable, reliable, and high-performance products. The ideal candidate brings deep expertise in mechanical design, materials, fluid dynamics, and manufacturing processes, with the ability to drive cross-functional development of integrated sensor systems used in the most demanding industrial/critical environments.

Essential Functions:

• Convert customer requirements into engineering requirements, design objectives, exploratory research topics, feasibility analyses, innovation opportunities, risk assessments, and comprehensive design specifications.
• Lead mechanical design of sensor components and systems with tight tolerance control and robust structural integrity.
• Utilize 3D CAD modeling and simulation tools to evaluate stress, vibration, heat transfer, and fluid flow characteristics influencing sensor performance.
• Develop material selection criteria emphasizing liquid compatibility, thermal stability, corrosion resistance, mechanical durability, and manufacturability.
• Specify and optimize manufacturing and assembly processes including injection molding, CNC machining, die casting, stamping, welding, crimping, over-molding, and adhesive bonding.
• Design leak-tight sealing systems using O-rings, gaskets, welded joints, and other sealing strategies suitable for critical industrial environments.
• Define and execute mechanical and environmental validation plans to verify performance, reliability, and compliance with industrial standards. Construct prototypes and design articles for verification and validation testing.
• Collaborate closely with electrical, firmware, and manufacturing teams leading the cohesive integration of mechanical, electronic, and sensing subsystems.
• Author and publish comprehensive engineering documentation, including detailed engineering drawings, design specifications, simulation results, tolerance analyses, test plans, FMEA, safety review, failure analysis reports, and bill of material cost.
• Apply core engineering principles-thermal analysis, fluid mechanics, strength of materials, and material science-throughout all development phases.
• Assess and integrate the latest technological developments by researching industry trends, vendor networks, competitors, and academic sources.
• Mentor junior engineers and contribute to continuous improvement of mechanical design methodologies and product development best practices.

Critical Success Factors:

• Technical Excellence:
  Apply deep mechanical engineering expertise to deliver robust, high-performance sensor designs. Robust design documentation of experimentation, analysis, verification and validation, and final design deliverables are key outcomes.
• Design for Manufacturability & Lifecycle Performance: Design with process capability, material behavior, and environmental durability in mind, ensuring long-term performance and cost efficiency. Sensor products that are easy to build, highly reliable, and maintain consistent performance throughout their operational life are key outcomes.
• Cross-Functional Collaboration:
  Integrate seamlessly with electrical, firmware, and manufacturing teams to ensure cohesive product development. Anticipation of team needs, successful production scale up, and on-time product launches are key outcomes.

Education & Experience Required:

• Bachelor's degree in Mechanical Engineering, Master's degree in Mechanical Engineering preferred.
• 10+ years of hands-on mechanical design experience, ideally in industrial instrumentation, electro-mechanical devices, or precision systems. Similar industrial background considered.
• Expert proficiency in 3D CAD (Solid Works preferred) and simulation tools for mechanical, thermal, and/or fluidic analysis (FEA/CFD).
• Proven experience in design for manufacturability (DFM) and design for assembly (DFA) across injection molding, machining, casting, welding and assembly processes.
• Strong background in mechanical design, fluid dynamics, thermodynamics, and mechanical behavior of materials under industrial operating conditions. Ideally critical applications where high reliability are essential.
• Established skills in sealing system design (O-rings, gaskets, welds) for high-reliability sensor housing, Ingress Protection (IPx) ratings, and pressure-rated assemblies.
• Familiarity with industry standards and regulatory compliance (examples: CE, UL, CSA, ASME, ISO, ASTM, MIL-STD, etc.) relevant to industrial instrumentation.
• Excellent analytical, problem-solving, and communication skills, with a track record of leading technically challenging design initiatives.

Desired Skills:

• Analytical & Problem-Solving - Decompose complex mechanical challenges, perform root cause analysis, and design innovative,…