Senior Mechanical Design Engineer

Job Title: Senior Mechanical Design Engineer

Location: Lake Forest, IL

Salary: $100,000 - $135,000 (based on experience)

Visa Sponsorship: Available (H-1B, L1, TN, and others)

About the Role:

We are seeking an experienced Senior Mechanical Design Engineer with 8-12 years of mechanical design experience, particularly in manufacturing-driven product development. This role requires a strong analytical mindset, a hands-on approach, and a passion for designing products that seamlessly transition from concept to production. The ideal candidate will be independent, data-driven, and capable of making informed design decisions without the need for constant direction.

Key Responsibilities:

• Lead mechanical design efforts with a strong focus on manufacturability and production feasibility.
• Utilize CREO for 3D modeling and drawings and manage design data within Windchill.
• Conduct Failure Mode and Effects Analysis (FMEA) and Geometric Dimensioning and Product and Process Review (GDPNR).
• Perform statistical analysis, including Design of Experiments (DOE) and Six Sigma methodology, to guide design decisions.
• Engage in lab testing, data analysis, and factory visits to ensure designs align with production capabilities and schedules.
• Drive new product development (NPD) and product launches, ensuring seamless design-to-production transitions.
• Develop established procedures and analysis databases to streamline processes and improve efficiency.
• Collaborate with factories and testing labs to optimize designs and resolve production challenges.

Qualifications & Skills:

• 8-12 years of experience in mechanical design, particularly in manufacturing and product development.
• Expertise in CREO for 3D modeling and Windchill for data management.
• Strong foundation in statistical analysis, DOE, and Six Sigma methodologies.
• Background in New Product Development (NPD) and product launches.
• Hands-on approach, with experience in lab testing, data validation, and factory assessments.
• Proven ability to work independently and proactively—no need for constant supervision.
• Experience in manufacturing sectors, particularly with hand tools, power tools, or mechanical products.
• Stable work history—ideally, candidates should have stayed at companies for at least 4-5 years.

Why Join Us?

• Work on innovative mechanical designs with a direct impact on manufacturing and product success.
• Join a team that values data-driven decision-making and independent problem-solving.
• Gain hands-on experience by working closely with labs and factories to refine and optimize designs.
• Be part of an organization that supports long-term career growth and stability.
• Competitive salary and visa sponsorship available for qualified candidates.

This is a critical role, and we are seeking a top-tier candidate who can hit the ground running. If you have the experience and expertise to make an immediate impact, we encourage you to apply!