Senior Mechanical Designer – R&D Engineering

Senior Mechanical Designer – R&D Engineering

Location: Sudbury, Ontario Base Salary: $95,000–$120,000 + Benefits

About the Opportunity

Our client is seeking an experienced Senior Mechanical Designer – R&D Engineering to join their engineering team. This is an exciting opportunity for a technically strong design professional to contribute to the development of innovative mechanical products and equipment, taking projects from initial concept through detailed design, prototyping, testing, validation, and final production release.

The successful candidate will play a key role in new product development, mechanical design, and continuous product improvement, bringing a practical, hands-on approach to engineering challenges. This position will also contribute to technical reporting, engineering documentation, and R&D project administration.

Key Responsibilities

· Lead mechanical design activities for new products, equipment, mechanical systems, structures, and product enhancements.

· Develop design concepts, 3D CAD models, detailed engineering drawings, bills of materials, specifications, and technical documentation.

· Design fabricated structures, weldments, sheet metal components, machined parts, mounting systems, and mechanical assemblies.

· Apply design-for-manufacturing, assembly, serviceability, reliability, safety, and cost-effectiveness principles.

· Perform engineering calculations and support structural analysis, FEA, prototype testing, and design validation.

· Participate in design reviews, risk assessments, DFMEA, test planning, and verification activities.

· Integrate mechanical, hydraulic, driveline, and purchased components into complete equipment systems.

· Collaborate with suppliers and manufacturing partners on technical requirements, prototypes, and design improvements.

· Support prototype builds and troubleshoot fitment, packaging, fabrication, assembly, and testing challenges.

· Investigate field issues, warranty concerns, and test findings, recommending practical design improvements.

· Provide technical guidance and mentorship to junior designers and engineering technologists.

· Assist with complex production-related engineering issues when specialized design expertise is required.

Engineering Documentation & Technical Reporting

· Prepare engineering reports, design summaries, technical justifications, test reports, and recommendations.

· Maintain clear documentation of design assumptions, calculations, technical challenges, alternatives, test results, and conclusions.

· Ensure engineering decisions are supported by technical analysis, testing, applicable standards, and documented engineering judgement.

· Communicate project progress, technical risks, findings, and recommendations to management and cross-functional teams.

R&D Project Documentation & Administration

· Maintain accurate and organized records for research and development projects, including technical objectives, uncertainties, experimental work, design iterations, testing, and engineering hours.

· Maintain traceable project documentation, including drawings, calculations, meeting notes, test data, photographs, revisions, and technical conclusions.

· Assist with the preparation of technical summaries and supporting documentation for applicable R&D tax incentive programs and related reviews.

· Work collaboratively with Engineering Management and Finance/Administration to ensure project records are complete and maintained throughout the development lifecycle.

Qualifications & Technical Experience

· Diploma or degree in Mechanical Engineering, Mechanical Engineering Technology, or a related discipline.

· Minimum 8 years of mechanical design experience, ideally within heavy equipment, industrial machinery, mobile equipment, or an OEM environment.

· Advanced proficiency with Autodesk Inventor or comparable 3D mechanical CAD software.

· Strong experience designing large assemblies, fabricated structures, weldments, sheet metal components, machined parts, and mechanical systems.

· Strong understanding of engineering drawings, GD&T, tolerancing, welding symbols, materials, fabrication, machining, and assembly processes.

· Ability to perform practical engineering calculations and select appropriate mechanical components and hardware.

· Experience with BOMs, ERP/MRP systems, engineering change processes, and controlled technical documentation.

· Familiarity with DFMEA, root-cause analysis, prototype testing, and design validation.

· Experience with mobile equipment, hydraulic systems, driveline components, structural analysis, or applicable industry standards is considered an asset.

· P.Eng. designation or eligibility for professional registration is an asset.

· Previous experience supporting R&D documentation or technical reporting for SR&ED claims is strongly preferred.

Communication & Leadership

· Excellent verbal and written communication skills, including technical report writing.

· Ability to communicate complex engineering concepts to both technical and non-technical stakeholders.

· Strong organizational and administrative skills, with attention to detail and documentation accuracy.

· Ability to manage multiple projects and competing priorities while maintaining accurate records.

· Demonstrated ability to work independently, take ownership, and provide regular project updates.

· Practical problem-solving skills and an understanding of real-world manufacturing constraints.

· Ability to mentor junior team members and contribute to engineering processes and continuous improvement.

Role Overview

This position is primarily focused on R&D engineering, new product development, mechanical design, prototyping, testing, validation, and technical documentation. The successful candidate will have the opportunity to contribute directly to product innovation while working closely with engineering, manufacturing, suppliers, and other internal stakeholders.