Mechanical Design Engineer

Senior Mechanical Test Development Engineer

Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world. A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment. If you are excited about a role but don't meet every bullet point, we encourage you to apply and join us to create the extraordinary.

To support our extraordinary teams who build innovative products and contribute to our growth, we are seeking a Senior Mechanical Test Development Engineer located in Austin, Texas.

Reporting to the Test Development Manager, the Senior Mechanical Test Development Engineer is responsible for designing, developing, and supporting mechanical solutions used in manufacturing test environments. This role focuses on the development of Automated Test Equipment (ATE), test fixtures, electromechanical mechanisms, and associated manufacturing test solutions used for Printed Circuit Board Assemblies (PCBAs) and High-Level Assemblies (HLAs).

The engineer will work closely with electrical, software, manufacturing, quality, and customer engineering teams to develop reliable, cost-effective, and scalable test solutions while supporting product introduction, production ramp, and ongoing manufacturing operations.

Required Qualifications

• Bachelor's degree in mechanical engineering or related engineering discipline.
• Minimum 5 years of experience in mechanical design, test development, manufacturing engineering, or related engineering disciplines.
• Demonstrated experience designing electromechanical fixtures and mechanical test mechanisms.
• Experience developing manufacturing test fixtures for PCBAs and/or high-level assemblies.
• Experience supporting automated test equipment (ATE) development and deployment.
• Experience working with fabrication suppliers, machine shops, and manufacturing teams.
• Experience with Pneumatic Fixture Design
• Experience with Bed-of-Nails Fixtures

Key Responsibilities

• Design and develop turnkey mechanical solutions for automated manufacturing test systems, including manual, semi-automated, and fully automated test equipment.
• Design electromechanical fixtures, mechanisms, and tooling used for functional testing of PCBAs and high-level assemblies.
• Develop robust mechanical interfaces that support reliable electrical connection, product alignment, and repeatable testing throughout the product lifecycle.
• Design fixture structures utilizing pneumatic, vacuum, spring-loaded, and other motion-control techniques as required.
• Support fixture standardization and modular design initiatives to improve development efficiency and long-term maintainability.

Mechanical Design & Documentation

• Create complete 3D CAD models, assembly drawings, detail drawings, and engineering documentation using Solid Works and related CAD tools.
• Generate and maintain Bills of Material (BOMs), Engineering Change Orders (ECOs), and associated documentation packages.
• Perform tolerance stack-up analysis, Design for Manufacturability (DFM), and Design for Assembly (DFA) reviews.
• Develop documentation sufficient for fabrication, assembly, maintenance, and field support activities.
• Ensure compliance with internal engineering standards and customer requirements.

Prototype Development & Validation

• Build, assemble, and validate prototype fixtures and mechanical subsystems.
• Conduct engineering evaluations, verification testing, and design validation activities.
• Analyze test results, identify root causes of failures, and implement corrective actions.
• Support reliability improvements through iterative design enhancement and validation testing.
• Document testing methodologies, results, lessons learned, and recommended design improvements.

Manufacturing & Supplier Support

• Interface with machine shops, fabrication vendors, and component suppliers to support fixture production.
• Review manufacturing processes and recommend improvements to reduce cost and improve quality.
• Support CNC machining operations and fabrication activities associated with fixture development.
• Utilize rapid prototyping and…