Senior Mechanical Engineer

Senior Mechanical Engineer - Automation & Custom Machine Building

Location: Sterling, MA

Compensation: Competitive salary with a broad range reflecting extensive experience, technical expertise, and leadership capabilities.

An established and growing Automation Systems Integrator specialising in custom machine building and systems integration is seeking a Senior Mechanical Engineer to join its team in Sterling, MA. This is a high-impact role designed for an experienced engineering professional with 10+ years of mechanical engineering experience who thrives in a project-driven environment and can lead mechanical design efforts from concept through commissioning.

The successful candidate will take ownership of complex automation projects, manage budgets and schedules, collaborate across multidisciplinary teams, and maintain strong professional relationships with customers, suppliers, and internal stakeholders while delivering innovative automation solutions.

• Lead and execute 3D CAD design work using On Shape , including detailed part and assembly modelling, drawing package development, and design-for-manufacturability reviews.
• Own mechanical system design from concept development through detailed design, build, testing, installation, and commissioning.
• Apply sound engineering principles to develop innovative, reliable, and cost-effective machine solutions for a wide variety of industries.

• Create, maintain, and manage Bills of Materials (BOMs) for active projects throughout all project phases, from concept through build and commissioning.
• Ensure BOM accuracy, completeness, and version control throughout the project lifecycle.
• Coordinate material requirements and support procurement activities to maintain project schedules.
• Apply and uphold internal and industry-standard engineering best practices across mechanical systems.
• Ensure appropriate material selection, tolerancing, fastening methods, and vendor component specifications.
• Contribute to the ongoing development and refinement of engineering design standards, procedures, and documentation.
• Solicit, evaluate, and manage quotations from fabrication and machining vendors for custom parts and assemblies.
• Assess supplier capabilities, lead times, quality standards, and cost competitiveness.
• Make sourcing recommendations and coordinate purchasing activities to support project execution.

• Execute projects within established budgets and schedules.
• Track mechanical engineering hours, material expenditures, and resource allocation against project estimates.
• Identify risks and variances early and actively participate in project reviews, planning sessions, and corrective actions.

• Partner closely with controls engineers, project managers, assembly technicians, and other stakeholders to ensure seamless system integration.
• Ensure mechanical designs are integration-ready and support efficient machine assembly, testing, and on-time delivery.

• Participate in Factory Acceptance Tests (FATs) with customers and internal teams.
• Support customer installations and commissioning activities as required.
• Build trusted relationships with customers through professional communication and technical expertise.

• Conduct detailed system analysis, testing, debugging, and troubleshooting activities.
• Identify root causes of mechanical issues and implement effective corrective solutions.
• Ensure automation systems operate safely, efficiently, and at optimal performance levels.

• Provide expert technical guidance and mentorship to engineers, technicians, and project teams.
• Deliver training and support to customers and internal personnel to ensure successful operation and maintenance of systems.
• Share best practices and support the continuous development of engineering capabilities across the organisation.

• Ensure all engineering activities comply with applicable regulations, industry standards, and customer requirements.
• Maintain a strong commitment to workplace safety and safe machine design principles.

• Bachelor's degree in Mechanical Engineering or a related technical discipline is required.

• 10+ years of mechanical engineering experience in automation, custom machine building, systems integration, special machinery, or related industrial environments.
• Proven experience delivering complex automation projects from concept through commissioning.
• Broad exposure across multiple industries is highly desirable.

• Extensive hands-on experience with On Shape or a comparable parametric CAD platform is required.
• Direct OnShape experience is strongly preferred.

• Demonstrated expertise managing structured BOMs, manufacturing documentation, and mechanical drawing packages throughout the complete project…