Sr. Mechanical Engineer

Position Summary: We are seeking a Senior Mechanical Engineer with a passion for complex machinery, advanced mechanical design, and systems integration. The ideal candidate will bring strong CAD modeling skills, in-depth knowledge of CREO, and proven experience working on large industrial equipment—especially in areas such as additive manufacturing, automated fiber placement, or custom machinery.

This is a key technical role focused on designing, analyzing, and improving the mechanical systems used in our next-generation machines and industrial 3D printers.

Employment Type: Full Time Salary

Key Responsibilities:

• Lead the mechanical design and development of complex machinery and large industrial systems.
• Utilize CREO CAD software to develop 3D models, detailed drawings, and assemblies.
• Perform engineering calculations, tolerance stack-ups, and materials selection.
• Collaborate with cross-functional teams including controls, software, electrical, and manufacturing engineering.
• Support integration of industrial 3D printing systems and automated fiber placement equipment into larger manufacturing environments.
• Conduct design reviews and mentor junior engineers.
• Assist in prototype assembly, testing, and troubleshooting.
• Ensure all designs meet safety, quality, and performance standards.
• Generate technical documentation including BOMs, specifications, and test procedures.
• Develop new designs to meet customer or marketing specifications.
• Works with supervision to maintain project schedules and budgets.
• Documents designs using the appropriate format to Ingersoll and/or customer standards.
• Provides assistance to other functional organizations, manufacturing, assembly, customer service, through the life of the project.
• May have responsibility for testing and validation of design.
• Develop specifications for purchased equipment.
• Prepare Bill of Materials and ENOC’s.
• Maintains technical competency and works to expand technical skills and knowledge.
• Approve detailed drawings produced by peers.
• Some travel is required for this position.

Qualifications:

• A Bachelor’s degree in an Engineering or Mechanical Engineering
  • Extensive experience without a degree will be considered.
• Minimum 8 years of experience in mechanical design engineering, preferably in capital equipment or heavy industry.
• Proficient in CREO (Parametric) CAD system and PDM tools.
• Strong background in mechanical systems, motion control, structural design, and thermal considerations.
• Demonstrated experience designing for manufacturability and assembly (DFMA).
• Preferred Experience
• Familiarity with hydraulic, pneumatic, and robotic systems integration.
• Experience with industrial-scale additive manufacturing (3D printing) or automated fiber placement systems.
• Hands-on experience with assembly, field installations, or system commissioning.
• Finite Element Analysis (FEA) skills using tools such as ANSYS or similar.
• Working knowledge of GD&T and ANSI/ASME Y14.5 standards.

Location & Compensation:

• Rockford, IL
• Pay: $90,000-$130,000 p/hr DOE
• Benefits package, including health, dental, vision, life insurance, and a 401(k) match.
• Join the team to work on groundbreaking projects known for its innovation.

About Lean Synergy: Lean Synergy Staffing is a Veteran-owned & operated recruiting firm dedicated to aligning top-tier talent with high-impact roles across diverse industries. Our team, comprised of experienced military professionals and industry specialists, brings a mission-driven approach to workforce solutions. With a specialized focus on placing skilled change management professionals, we help organizations navigate transformation with precision. We are committed to supporting transitioning service members, veterans, military spouses and civilian professionals by providing access to meaningful, long-term career opportunities that drive success for government, public and private sector clients.