Product Development Engineer (Machine Design Specialist)

Flexicon is seeking Product Development Engineer to join our Lehigh Valley engineering team. This role focuses on the design, analysis, and validation of complex machinery and integrated systems, transitioning projects from initial concept through to manufacturing hand-off.

Engineering Environment & Lifecycle

The Product Development team at Flexicon manages the full lifecycle of industrial machinery. The work involves engineering robust mechanical structures, integrating electro-mechanical control systems, and developing fluid power solutions for heavy-duty bulk material handling equipment.

Core Responsibilities

Key responsibilities include:

• Machine Design & Analysis: Conduct advanced structural validation using FEA (Finite Element Analysis) and kinematic simulations. Ensure the integrity of heavy-duty steel fabrications and mechanical drivetrains.
• Systems Integration: Design and implement electro-mechanical controls, including the selection and integration of motors, drives, and sensors.
• Fluid Power Development: Develop and validate hydraulic and pneumatic fluid power systems for automated machinery functions and material flow control.
• Fabrication Design: Optimize designs for mechanical steel fabrication processes, including welding, machining, and assembly, ensuring manufacturability and cost-efficiency.
• Validation & Testing: Coordinate the assembly of integrated prototypes and execute performance testing to verify mechanical, electrical, and fluid power specifications.
• Technical Resource: Act as a subject matter expert in mechanical systems and machine design, providing technical guidance and mentoring to junior engineering staff.

Technical Requirements

• Professional Experience: Minimum of 5 years in a dedicated machine design, product development, or R&D role. 10 years of experience in complex industrial equipment is highly preferred.
• Education: Bachelor’s degree in Mechanical Engineering or a related technical discipline.
• Technical Expertise:
• Strong background in fundamental machine design and mechanism development.
• Practical knowledge of electro-mechanical components and control logic.
• Working knowledge of hydraulic and pneumatic system design and troubleshooting.
• Understanding of steel fabrication techniques, weldment design, and industrial finishes.
• Analysis Tools: Proven proficiency in simulation software (e.g., ANSYS, MATLAB) for structural and kinematic optimization.
• Design Tools: Mastery of 3D parametric modeling (Autodesk Inventor / SolidWorks).

Position Details

• Classification: Full-time, Exempt.
• Physical Location: Bethlehem, PA.
• Hybrid Schedule: Professional hybrid environment (approx. 60% WFO / 40% WFH).
• Career Structure: Structured engineering tiers provide a clear path for advancement.

Application & Technical Interview

We prioritize a technical review of prior work. Candidates should be prepared to discuss specific machine design challenges where your analysis or systems integration (controls, fluid power, or structural modeling) directly influenced the final engineering outcome.