Lead Mechanical Design Engineer

About the Role:
The Lead Mechanical Design Engineer, also known as Senior Mechanical Engineer or Mechanical Product Development Engineer, is responsible for leading full-cycle product design and development for advanced downhole tools and high-pressure mechanical systems. This role drives innovation, manages complex design projects from concept through qualification, and ensures products meet performance, reliability, and safety standards. The position offers an opportunity to lead engineering initiatives that directly impact product performance, manufacturing efficiency, and long-term reliability.

Responsibilities:

• Lead the full product development lifecycle, from concept through prototype qualification and production release, using structured project management methods.
• Create conceptual designs that expand product technology and transform innovative ideas into manufacturable, high-performance solutions.
• Serve as a technical authority, mentoring engineers and designers while reviewing and approving mechanical designs and documentation.
• Plan, execute, and document qualification tests for high-pressure, thermal, and mechanical performance, analyzing results to refine designs.
• Conduct design reviews to verify safety, reliability, and compliance with performance requirements.
• Collaborate with manufacturing teams to optimize manufacturability, assembly efficiency, and cost through DFMA principles.
• Oversee prototype builds, ensuring robust assembly documentation, component traceability, and quality assurance standards.
• Configure and operate data acquisition systems for testing, capture and analyze performance data, and drive design improvements.
• Maintain engineering documentation through PDM, including SolidWorks models, drawings, and revision-controlled files.
• Champion continuous improvement and standardization of design best practices across the engineering team.

Qualifications:

• Bachelors degree in Mechanical Engineering or related discipline from an accredited institution.
• 10 or more years of mechanical design and development experience in high-pressure or harsh environment equipment, ideally in the oil and gas or energy sector.
• Strong proficiency in SolidWorks, including 3D modeling, detailed drawings, GD&T, and design documentation.
• Demonstrated expertise in structural and thermal FEA, tolerance analysis, and mechanical stress evaluation.
• Proven ability to lead design verification and qualification programs, including test planning, execution, and analysis.
• Experience with materials selection, metallurgy, and sealing technologies for high-pressure applications.
• Hands-on experience with electromechanical integration, sensor design, and packaging for downhole or ruggedized environments.
• Excellent communication skills, with the ability to lead design reviews and produce technical reports.

Desired Qualifications:

• Masters degree in Mechanical Engineering or a closely related field.
• Background in oilfield tools, completions, or drilling equipment design and testing.
• Proficiency with DFMA, reliability engineering, and design-for-test methodologies.
• Familiarity with ASME and API standards for pressure-containing equipment.
• Experience with root cause analysis, FMEA, and continuous improvement processes.
• Strong project management and leadership skills with the ability to guide cross-functional teams.