Senior Mechanical Engineer

Role Description

The Senior Mechanical Engineer will lead the design, development, and optimization of mechanical systems and components that support mission-focused hardware solutions. This full-time, on-site role in the Greater Seattle Area involves owning mechanical design from concept through production manufacturing, including requirements definition, CAD modeling, analysis, prototyping, testing, DOE, and design iteration. Must have experience in electronic packaging of PCB and FPC within enclosures. The Senior Mechanical Engineer will collaborate closely with cross-functional teams, coordinate with project stakeholders, and provide technical guidance to other engineers to ensure systems are reliable, manufacturable, and aligned with operational needs.

Daily responsibilities include reviewing design specifications, performing engineering calculations, design activities, overseeing vendor interactions, and contributing to continuous improvement of engineering processes and standards.

Principal Responsibilities

• Partner with Engineering Management to develop the processes and procedures that facilitate high-quality, market-leading products, developed on-time and on-budget by a team of energetic, focused, and driven technical experts.
• Collaborate with Product and Program Management, Systems Engineering, and other cross-functional teams to assess viability of new product features and design a mechanical architecture for the product.
• Collaborate with system program management to assess and develop project schedules and milestones, and identify risks and mitigation plans.
• Direct all aspects of mechanical design with minimal supervision.
• Mentor, coach, and train early-career engineers and peers.
• Partner with product design and system architects to review and clarify design requirements and define the appropriate mechanical and thermal architecture.
• Expertly assemble prototypes and verify form, fit, and function.
• Work with and manage external component suppliers and manufacturers.
• Track test progress, bugs, and fixes, and drive changes to design based on resolution.
• Perform other duties as required.

Basic Qualifications

• BS in Mechanical Engineering or equivalent experience.
• 7+ years in mechanical engineering in product development.
• Expert in 3D CAD, OnShape/Creo/SolidWorks and can manage complex parts & assemblies.
• Lead Design Engineer on multiple high-volume, mass-manufactured electro-mechanical products taken through to launch — demonstrable ownership from concept to volume production.
• Engineering consultancy or client-services experience — comfortable quoting work, developing product specifications, documenting design history, and working directly with external clients and partners.
• Experience designing under quality standards such as AS91xx, SAE, ISO or other highly-regulated environments. Vigilant frequently designs and consults for partners developing regulated devices, so prior defense or aerospace hardware experience is expected.
• Demonstrated ability to create production data sets that fully define manufacturing requirements.
• Proven examples of designing to meet budgets and rigid timelines.
• Ability to work on numerous projects concurrently and navigate shifting requirements.
• Ability to self-manage and work directly with clients, vendors, and design teams.
• Strength in predictive modeling, including FEA and tolerance analysis.
• General machine shop knowledge.
• Ability to listen to client and company needs and add value through billing efficiency.
• Ability to travel and support clients and factories (less than 15%).
• Ability to own BOMs and write manufacturing contracts.
• Can solve complex problems while displaying technical creativity.
• Experience leading technical teams, cross-functional groups, and vendors regarding project plans.
• Strong communication and interpersonal skills.
• Proven ability to quickly learn new technologies and collaborate with partners to deliver outstanding results.
• Comprehensive understanding of the product development, validation, and support lifecycle for a complex vertical product.
• Ability to meet Vigilant Engineering customer and/or government security screening and background check requirements.

Preferred Qualifications

• Direct consumer electronics experience (strong plus), including circuit design, PCB layout, component specification, and sourcing.
• Thorough knowledge of injection molding tooling, metal design, handheld electronics, and computer design.
• Experience in automation, mechatronics, and kinematic assemblies.
• Product test design, documentation, and implementation.
• PFMEA, DFMEA, RC/FA, and compliance experience.
• Master's degree in an engineering-related field.
• Experience in domestic and overseas manufacturing.
• Demonstrated end-to-end product development experience, from early design through shipping and support of real-world customers.