Senior Design Engineer

We are seeking a Senior Design & CFD Engineer to lead the development, validation, and optimization of digital twin models for our internally designed atomization systems. This is a high-impact role requiring deep expertise in fluid dynamics, mechanical design, and system-level engineering. The right candidate will take full ownership of modeling and design efforts that directly influence system performance and next-generation technology development.

The Senior Design & CFD Engineer will design, analyze, and optimize complex mechanical systems used in advanced metal processing applications. This role combines hands-on mechanical design with advanced multi-physics simulation (CFD), focused on high-temperature gas flows, controlled atmospheres, and vacuum systems.

The ideal candidate is a technically strong, self-directed engineer who thrives in a fast-paced, collaborative environment and can drive projects from concept through production with minimal oversight.

Key Responsibilities

Digital Twin & CFD Leadership

• Develop, validate, and continuously improve multi-physics CFD models using Ansys Fluent (or similar platforms).
• Simulate high-temperature gas flows involving multiple inert gases, subsonic and supersonic velocities, and vacuum conditions.
• Model complex thermo-fluid interactions relevant to metal atomization processes.
• Translate simulation results into actionable design improvements and performance optimization strategies.

Mechanical Design & System Development

• Design and detail mechanical systems and subassemblies including weldments, piping, pressure systems, hydraulics, pneumatics, and motion systems.
• Develop robust design concepts and detailed fabrication drawings aligned with performance, safety, and manufacturability requirements.
• Perform extensive 3D CAD modeling and 2D detailing (SolidWorks preferred).
• Ensure design integrity through verification, peer reviews, and adherence to engineering standards.

  Cross-Functional Collaboration & Execution

• Collaborate with engineering, manufacturing, procurement, and project management teams to ensure seamless design integration into production.
• Provide technical leadership during drafting, fabrication, and system commissioning phases.
• Support supplier selection and purchasing by defining technical requirements and evaluating capabilities.
• Manage assigned design projects, including cost estimation, scheduling, and progress tracking.
• Troubleshoot design and production challenges, implementing practical, data-driven solutions with accountability for results.

Required Qualifications

• Bachelor’s degree in mechanical engineering (BSME) or equivalent required.
• 5+ years of experience in mechanical system design.
• Demonstrated experience with CFD modeling of thermo-fluid systems.
• Experience working with vacuum systems, controlled atmospheres, high-temperature gas systems, or similar environments.
• Strong proficiency in SolidWorks (or comparable 3D CAD platform).
• Strong proficiency in Ansys Fluent or comparable CFD software.
• Working knowledge of GD&T (Geometric Dimensioning & Tolerancing).
• Familiarity with metals including carbon steel, stainless steel, copper, brass, aluminum, and engineering plastics.
• Understanding of fabrication and joining methods: welding, threading, forming, brazing.
• Experience integrating motors, sensors, actuators, hydraulics, and pneumatics into mechanical systems.
• Proficiency in Microsoft Office and engineering documentation tools.

Preferred Qualifications

• Experience in metal atomization, powder processing, or additive manufacturing.
• Experience developing and maintaining digital twin models.
• Experience working in startup or fast-growth environments.
• Master’s degree in mechanical engineering or related field (CFD focus a plus).

Desired Candidate Qualities

• Strong analytical and problem-solving capabilities for complex, multidisciplinary challenges.
• Ability to clearly communicate technical findings to both engineering and non-technical stakeholders.
• High level of ownership and accountability.
• Organized, detail-oriented, and quality-driven.
• Adaptable and comfortable working in a dynamic, evolving technical environment.

Work Environment & Physical Requirements

• Primarily office-based with periodic time on the manufacturing floor.
• Ability to sit, stand, walk, and bend for extended periods.
• Occasionally required to lift or move up to 25 lbs.
• May be required to reach, climb, balance, stoop, kneel, crouch, or crawl.
• Requires close vision, color vision, and depth perception.

Travel:

Occasional domestic travel may be required.