Senior Mechanical Design Engineer

ProPhotonix designs and manufactures LED illuminators and line-light products for the machine vision market, with approximately 70% of business in custom and OEM solutions. This role exists to lead the mechanical and product design of LED light engines — including associated manufacturing and assembly fixtures — from concept through to manufacture, ensuring designs meet thermal, electrical, and manufacturability requirements, and integrate correctly with the optical design. The Mechanical Design Engineer works closely with electronics and optical engineering, the Project Manager, production, and procurement to bring new and custom LED illumination products to market.

• Acts as the senior mechanical-design subject-matter expert for assigned projects, providing technical direction on design trade-offs, materials, tolerancing, thermal management, and manufacturability.
• Leads mechanical design reviews and contributes to risk assessments, design verification, and design-transfer activities.
• Identifies design, quality, cost, supply, and manufacturability risks early and recommends practical mitigation actions.
• Contribute to broader product design activities across the light engine and illuminator range, from initial concept through to production release
• Produce and maintain 3D CAD models, assembly drawings, and manufacturing documentation
• Support thermal management design of LED assemblies, including heat sink design, thermal interface materials, airflow considerations and water cooling solutions
• Lead or support DFM/DFA reviews with production and procurement to ensure designs are manufacturable and cost-effective
• Select materials and finishes appropriate for thermal and mechanical performance, including corrosion and galvanic compatibility considerations
• Support prototyping, testing, and validation of new designs, including environmental and reliability testing
• Provides mechanical-design input and supporting technical documentation for product compliance activities, including CE, RoHS, IEC 62471 and EMC requirements, working with Quality/Compliance and the relevant technical functions. 

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or related discipline required; Master's degree preferred
• 10+ years Proven industry experience in mechanical/design engineering, ideally within electronics, optics, photonics, or precision manufacturing

• Strong 3D CAD skills (SolidWorks essential), including tolerancing and drawing standards (GD&T)
• Practical understanding of manufacturing processes (machining, die casting, sheet metal, injection molding, aluminum extrusion design) and DFM principles
• Experience designing fixtures, jigs, and tooling for assembly, test, or production processes
• Ability to design for thermal performance in electronics/LED assemblies
• Desirable: experience with thermal modelling/simulation tools (e.g. SolidWorks Thermal, or similar)
• Desirable: working knowledge of electronics (PCB layout awareness, basic circuit understanding, component packaging constraints)
• Desirable: Awareness of optical design or optomechanical assemblies (lenses, reflectors, beam-shaping optics)
• Desirable: familiarity with LED technology and photonics
• Desirable: understanding of relevant compliance standards (CE marking, RoHS, EMC, IEC 62471)