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.

Position Overview

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.

Key Responsibilities

Mechanical Design & Engineering

• Lead and execute 3D CAD design work using OnShape, 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.

Bill of Materials (BOM) Management

• 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.

Engineering Standards & Best Practices

• 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.

Vendor Management & Custom Part Procurement

• 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.

Budget & Schedule Management

• 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.

Cross-Functional Collaboration

• 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.

Customer-Facing Support

• 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.

System Analysis & Troubleshooting

• 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.

Technical Leadership, Support & Training

• 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.

Compliance & Safety

• 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.

Qualifications

Education

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

Experience

• 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.

CAD Expertise

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

BOM & Technical Documentation

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

Vendor & Procurement Experience

• Strong experience sourcing custom fabricated and machined components.
• Ability to critically evaluate supplier quotations, manage vendor relationships, and balance quality, cost, and delivery requirements.

Project Delivery

• Consistent track record of delivering engineering projects on schedule and within budget.
• Experience working within project-based, job-shop, or custom manufacturing environments.
• Familiarity with change order management processes is advantageous.

Small Company / Integrator Environment

• Comfortable operating in a lean, entrepreneurial, and fast-paced environment.
• Willing to take ownership, wear multiple hats, and drive projects independently.
• Previous experience with a small automation integrator or custom machine builder is strongly preferred.

Communication & Leadership

• Strong verbal and written communication skills.
• Ability to confidently interact with customers, suppliers, project teams, and executive stakeholders.
• Demonstrated ability to influence outcomes, solve problems collaboratively, and lead technical discussions.

Work Environment

• Daily work is performed within an office and manufacturing/shop-floor environment.
• Occasional travel to customer sites may be required for installation, commissioning, troubleshooting, and service support.
• Travel may involve overnight stays, extended hours, and occasional evening or weekend work in manufacturing or production environments.

Core Values

Champion the Customer

Build partnerships, do what is right, and win together.

Own It

Take accountability, solve problems, and drive results.

Deliver Excellence

Take pride in craftsmanship, demonstrate expertise, and maintain exceptional attention to detail.

Spark Innovation

Remain curious, embrace challenges, and pursue continuous improvement.

Stronger Together

Respect others, support teammates, and foster a collaborative, high-performing environment.

Why Join?

This role offers the opportunity to take full ownership of challenging automation projects and see them through from concept to completion while working alongside a highly skilled team of automation professionals.

Benefits include:

• Competitive salary with annual bonus potential
• Significant opportunities for career progression and technical growth
• Collaborative, low-bureaucracy environment where contributions directly impact project success
• Exposure to diverse industries, technologies, and custom machine applications
• Opportunity to work on technically complex automation solutions that solve real-world manufacturing challenges
• A culture that values craftsmanship, accountability, innovation, and teamwork
• Access to expanded automation capabilities through a larger platform of specialised engineering organisations