Sr. Mechanical Engineer (Staff)

Insight Global • Auburn Hills, MI • 1h ago

Job Description

Position Overview

The Senior Mechanical Engineer will lead the design, development, and industrialization of mechatronic systems and precision mechanisms used in high volume consumer electronic products. This role plays a critical function from concept through mass production, working cross functionally with electrical, firmware, manufacturing, and quality teams to deliver robust, scalable, and cost effective designs.

The ideal candidate has deep experience in mechanism design, electromechanical integration, tolerance stack up, and manufacturing readiness within fast paced, high mix, high volume environments.

Key Responsibilities

Product Design & Mechatronics Development

Design and develop mechanical and electromechanical systems, including mechanisms, actuators, housings, linkages, and precision assemblies.

Own mechatronic system integration, collaborating closely with electrical and firmware teams to ensure seamless hardware software interaction.

Lead design efforts from early concept, prototyping, and validation through production ramp and sustaining engineering.

Apply DFMEA, PFMEA, and robust design methodologies to ensure reliability and manufacturability.

Mechanisms & Precision Engineering

Design and validate precision mechanisms such as hinges, sliders, latches, gear systems, springs, and motor driven assemblies.

Perform tolerance analysis, stack ups, and GD&T to ensure functional performance at scale.

Evaluate materials, finishes, and coatings with a focus on durability, cost, and consumer facing aesthetics.

Support reliability testing, lifecycle testing, and failure analysis.

High Volume Manufacturing Support

Partner with manufacturing, operations, and supply chain teams to support DFM/DFA, yield improvement, and production scalability.

Support proto@type builds, EVT/DVT/PVT phases, pilot runs, and full production launches.

Diagnose and resolve manufacturing issues related to mechanisms, assembly processes, or supplier provided components.

Lead continuous improvement efforts to improve quality, cost, and throughput in mass production.

Cross Functional Leadership

Act as a mechanical technical lead on cross disciplinary product teams.

Interface with suppliers and contract manufacturers on tooling, fixtures, and process capability.

Mentor junior engineers and contribute to mechanical design standards and best practices.

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or recruiting process, please send a request to HR@insightglobal.com.To learn more about how we collect, keep, and process your private information, please review Insight Global's Workforce Privacy Policy: https://insightglobal.com/workforce-privacy-policy/.

Skills and Requirements

Required Qualifications

Bachelor's or Master's degree in Mechanical Engineering or related field.

8+ years of mechanical engineering experience in consumer electronics or high volume electromechanical products.

Strong background in mechatronics and precision mechanism design.

Hands on experience taking products from proto@type to mass production.

Proficiency in 3D CAD (SolidWorks, Creo, NX, or equivalent).

Strong understanding of GD&T, tolerance analysis, materials, and manufacturing processes.

Experience working with high volume manufacturing working with partners and suppliers. Preferred Experience

Consumer electronics product experience (wearables, mobile devices, smart devices, home electronics, peripherals).

Motorized systems, sensors, actuators, and electromechanical assemblies.

Plastic injection molding, die casting, stamping, and precision machining.

Experience supporting automation, test fixtures, or assembly tooling.

Exposure to reliability testing (drop, vibration, thermal, humidity).

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