Principal Mechanical Design Engineer

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The Principal Mechanical Design Engineer designs and analyzes mechanical parts, systems, equipment, and packaging that achieve desired cost, requirements, schedule, and performance objectives. Conducts feasibility studies, generates concepts, builds prototypes, and performs testing on new and modified designs. Conducts design capability evaluations (theoretical and empirical), as well as product life and reliability analyses. Performs root‑cause failure analysis. Determines and selects appropriate materials, as well as fabrication, manufacturing, and finishing methods for parts and assemblies.

Supports personnel in the preparation of detailed design, design testing and prototype fabrication. Interfaces with clients to assist in the gathering of requirements and objectives, as well as to deliver status updates. Provides design information to drafting for documentation.

• Integrates technical requirements within program constraints to create high level mechanical solutions.
• Interfaces and coordinates with other engineering disciplines – EE’s, SWE, Systems.
• Discusses challenges with manager and client, and generates architectural roadmaps.
• Gathers, defines, and documents mechanical system and subsystem requirements and objectives.
• Performs feasibility studies.
• Develops multiple design concepts and performs cost‑benefit analysis to determine best concept.
• Performs design reviews in accordance with project and company standards.
• Determines appropriate materials, manufacturing and assembly methods required to meet the design objectives.
• Interfaces and communicates with fabrication houses to review and make appropriate tradeoffs.
• Builds and tests representative prototypes.
• Generates robust mechanical designs suitable for production.
• Creates reliable, elegant system designs. Solves complex problems in a manner that meets program needs (technical, schedule, budget, product cost, production volume, reliability).
• Creates detailed 2D part and assembly drawings using appropriate ASTM and GD&T standards.
• Defines and conducts product performance, life, and reliability testing. Evaluates the results of testing.
• Performs worst case analysis on parts and systems.
• Performs root‑cause analysis on part and system failures and proposes design improvements.
• Defines and writes production test and validation requirements.
• Assists in the transition of product designs from R&D into Manufacturing.
• Determines, drives, and optimizes changes where required.
• Creates and implements design change orders.
• Sphere of influence is project wide and interdisciplinary, serves as expert reviewers for other projects.
• Outlines and generates high quality technical status updates and reports suitable for client.
• Coordinates and leads internal and client‑facing technical meetings.
• Mentor junior mechanical engineers.
• Performs other duties as assigned.

The functions/responsibilities outlined in this Job Description have an impact to D&K’s QMS and product quality.

Typically requires a minimum of 8 years of related experience with a Bachelor’s degree; or 6 years and a Master’s degree; or a PhD with 3 years’ experience; or equivalent experience.

• Excellent interpersonal skills for collaboration and teamwork (internally and with clients).
• Excellent communication and presentation skills (written and oral).
• Excellent grasp of fundamentals of mechanical engineering and systems development.
• Understanding and proficient use of 2D and 3D CAD software and file management, along with the associated analyses tools such as FEA (particularly in Solid Works).
• Understanding of mechanical engineering FUNDAMENTALS and analyses (mechanics of solids, dynamics, fluid dynamics, thermal dynamics, material science, physics, chemistry, engineering statistics, basic electronics, mathematics, vibrations, etc.).
• Knowledge and understanding of modern FABRICATION, rapid prototyping, and manufacturing processes, along with when and how to most effectively use them (standard…