Senior Mechanical Design Engineer

Summary

GEP Power Products, a leading manufacturer of ruggedized low-voltage power distribution components for the heavy-duty and off-road industries, is seeking a hands-on Senior Design Engineer

with strong mechanical design expertise in injection molding and electrical-mechanical assemblies. This role will lead the development of innovative power distribution solutions from concept through production. The ideal candidate is highly collaborative, quality-focused, and thrives in a fast-paced, high-mix environment.

Essential Duties and Responsibilities

This list of duties and responsibilities is not all inclusive and may be expanded to include other duties and responsibilities as management may deem necessary from time to time.

Key Responsibilities

Product Design & Engineering Leadership

o   Own full lifecycle of mechanical product development—from napkin sketch to production release.

o   Independently lead design and development of ruggedized electrical-mechanical components, including housings, enclosures, connectors, and brackets, with a strong focus on injection-molded and overmolded parts.

o   Spearhead the selection and integration of mechanical components in low-voltage power distribution systems (e.g., busbars, seals, fasteners, thermal management elements).

o   Create and maintain accurate 3D models, 2D drawings, and documentation using PTC Creo and Windchill (or similar PLM tools).

o   Ensure mechanical integrity through structural analysis (hand calcs and FEA), critical dimensioning, tolerance stack-ups, and GD&T.

Project Ownership & Cross-Functional Coordination

o   Serve as the project engineering lead for major customer and internal development efforts—setting milestones, coordinating cross-functional deliverables, and owning design release deadlines.

o   Work closely with the VP of Engineering (you) to translate high-level product requirements into actionable engineering tasks and timelines.

o   Collaborate with customers and account managers to define and clarify mechanical requirements, propose design solutions, and support engineering review meetings.

o   Interface with toolmakers and molding suppliers for DFM, tool kickoffs, trials, and validation builds.

Manufacturing & Quality Integration

o   Support the qualification of molded and assembled components via PPAP, dimensional inspection, and first article reviews.

o   Work hands-on with internal and external teams to root-cause and resolve production issues, field returns, and supplier defects.

o   Develop detailed work instructions and visual aids for assembly and testing as needed.

Innovation, Cost Reduction & Continuous Improvement

o   Contribute to our culture of innovation by identifying opportunities for new products, feature enhancements, or modular design reuse.

o   Proactively suggest design or material changes that reduce tooling complexity, part count, or BOM cost without sacrificing durability or function.

o   Stay current on materials, fasteners, sealing methods, and design trends relevant to off-road and outdoor electrical enclosures.

Mentorship & Technical Influence

o   Act as a mentor to junior designers and engineering technicians—providing feedback, reviewing drawings, and guiding best practices.

o   Help refine our internal design standards, drawing practices, and documentation processes.

o   Support engineering process improvement initiatives like better tolerance control, critical dimension tracking, or early DFM collaboration.

Qualifications

Education

o   Bachelor’s Degree in Mechanical Engineering or related field.

Experience

o   Minimum 5 years of experience in mechanical product design—preferably in off-road, automotive, or industrial applications. Prior experience in electrical-mechanical systems and/or plastic component development is strongly preferred.

Technical Skills

o   Proficient in PTC Creo (preferred), SolidWorks also acceptable.

o   Hands-on experience with Ansys or similar FEA tools.

o   Strong understanding of injection molding, DFM/DFA, and GD&T.

o   Familiar with PPAP, FMEA, and ECN processes.

o   Comfortable with both rapid prototyping and production release cycles.

Soft Skills

o   Excellent problem-solving skills.

o   Strong communication and documentation abilities.

o   Highly self-motivated with the ability to drive projects independently.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is frequently required to sit; use hands to finger, handle, or touch objects, tools, or controls; and talk or hear. The employee is occasionally required to stand, walk, and reach above shoulders. The employee must occasionally lift and/or move drawings, files, parts, components, and manuals weighing up to 25 pounds. Specific vision abilities required by this job include close vision, depth perception, and the ability to adjust focus.

Work Environment

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.