Position Overview
LaserStar Technologies is seeking an experienced Lead Mechanical Design Engineer to lead the design and development of advanced industrial laser systems used for welding, marking, cutting, deep engraving, and precision motion-control applications.
This position will serve as the technical leader for mechanical design projects from concept through production release while collaborating closely with electrical, software, optical, manufacturing, service, quality, and purchasing teams. The ideal candidate enjoys hands-on engineering, solving complex technical problems, mentoring engineers, and developing innovative, manufacturable products.
Key Responsibilities
Mechanical Design & Product Development
- Lead the mechanical design and development of industrial laser systems, electromechanical assemblies, and automation equipment from concept through production.
- Design laser enclosures, sheet metal assemblies, weldments, machined components, fixtures, tooling, XYZ motion systems, rotary systems, and precision mechanical assemblies.
- Design and integrate opto-mechanical assemblies, including beam-delivery components, optical mounts, beam expanders, protective windows, and related hardware.
- Develop complete SolidWorks models, assemblies, configurations, manufacturing drawings, and bills of materials using proper GD&T practices.
Motion Systems & Precision Engineering
- Design precision linear and rotary motion systems using stepper motors, ballscrews, linear guides, gearboxes, and positioning components.
- Perform engineering calculations, including tolerance stack-ups, fit and clearance analysis, load calculations, thermal evaluations, and mechanical performance assessments.
Prototype Development & Validation
- Lead prototype builds, product validation, testing, troubleshooting, and design refinement.
- Develop validation plans and ensure products meet functional, reliability, quality, safety, and manufacturability requirements.
- Support prototype fabrication, laboratory testing, production startup, and continuous product improvement.
Manufacturing & Production Support
- Apply Design for Manufacturability (DFM) and Design for Assembly (DFA) principles throughout product development.
- Support manufacturing with tooling improvements, assembly methods, work instructions, production troubleshooting, and continuous improvement initiatives.
- Participate in root-cause investigations and implement corrective and preventive design solutions.
Technical Leadership
- Lead mechanical engineering projects from concept through production release.
- Conduct formal design reviews and provide technical guidance to engineers and technicians.
- Review engineering drawings, calculations, test results, and technical documentation.
- Mentor junior and mid-level mechanical engineers while promoting engineering best practices and design standards.
Cross-Functional Collaboration
- Collaborate closely with Electrical Engineering, Software Engineering, Manufacturing, Quality, Service, Purchasing, and Operations to ensure successful product integration and production readiness.
- Work with external suppliers and contract manufacturers to source components, evaluate manufacturability, review quotations, resolve technical issues, and support prototype and production builds.
- Support customer meetings, application reviews, design discussions, Factory Acceptance Tests (FAT), and occasional onsite customer visits as required.
Documentation & Configuration Management
- Create and maintain engineering drawings, specifications, bills of materials, test procedures, engineering change documentation, and technical reports.
- Maintain engineering documentation, revision control, product configurations, and released documentation through SolidWorks PDM or equivalent document-management systems.
- Ensure compliance with company engineering standards, FDA Class 1 laser safety requirements, machine-guarding standards, and applicable industry regulations.
Minimum Qualifications
- Bachelor's degree in Mechanical Engineering or a related engineering discipline.
- 8–12 years of mechanical engineering experience in product design and development.
- Advanced proficiency with SolidWorks, including complex assemblies, configurations, and manufacturing drawings.
- Demonstrated experience leading engineering projects from concept through production release.
- Strong understanding of GD&T (ASME Y14.5), tolerance analysis, and mechanical design principles.
- Experience troubleshooting complex electromechanical systems.
- Excellent communication, organizational, and problem-solving skills.
- Ability to mentor engineers and provide technical leadership.
- Must be authorized to work in the United States.
Preferred Qualifications
Experience with the following is preferred:
- Industrial laser systems
- Plastic and injection-molded components
- Root-cause and corrective-action investigations
- Precision motion systems
- Pneumatic systems
- SolidWorks PDM or equivalent Product Data Management software
- Opto-mechanical design
- Cable routing and harness integration
- FDA Class 1 laser systems or similar industrial equipment
- Sheet metal design
- Prototype fabrication and validation
- Vendor and supplier collaboration
- Weldment design
- Design for Manufacturability (DFM)
- Factory Acceptance Testing (FAT)
- Machined component design
- Design for Assembly (DFA)
- Industrial automation, robotics, or precision manufacturing
Pay: $125,000.00 per year
Work Location: In person
