Mechanical Engineer in Colorado Springs, Colorado at OPTICAL ENGINES INC

Job Description: Mechanical Engineer

Optical Engines Inc. (OEI) | Colorado Springs, Colorado

Reports to: Mechanical Engineering Manager or designated engineering lead.

Position Type: Full-time, on-site Experience Level: Mid-level; generally 3+ years of relevant experience.

Position Summary

Optical Engines Inc. is seeking a hands-on Mechanical Engineer to design, develop, analyze, prototype, test, and improve precision mechanical components and assemblies supporting advanced laser, photonics, fiber-optic, and electro-optical systems.

Working closely with optical, electrical, RF, systems, and manufacturing engineers, this position translates system requirements into practical mechanical solutions that meet demanding performance, thermal-management, reliability, packaging, and manufacturability requirements.

The Mechanical Engineer will independently own assigned designs and engineering projects, taking hardware from initial CAD development through fabrication, assembly, integration, testing, and production support.

Key Responsibilities

1. Mechanical Design and Engineering

• Design and develop mechanical components, assemblies, enclosures, fixtures, mounting structures, and precision optomechanical hardware.
• Create 3D CAD models, engineering and assembly drawings, and bills of materials using SolidWorks or comparable software.
• Translate system requirements into mechanical specifications, interfaces, tolerances, and design solutions.
• Select appropriate materials, fasteners, finishes, and manufacturing processes based on performance, cost, and reliability.
• Design mechanical interfaces supporting optical alignment, component stability, fiber routing, and system integration.
• Maintain accurate engineering documentation, revision control, and change records.

2. Engineering Analysis and Thermal Management

• Design and evaluate thermal-management solutions, including heat sinks, cooling plates, and thermal interfaces for laser and electronic systems.
• Perform engineering calculations involving heat transfer, structural loads, stress, deflection, vibration, and material properties.
• Apply finite element analysis (FEA), thermal simulation, and other engineering tools to validate designs.
• Evaluate thermal expansion, dimensional stability, mechanical alignment, and component interfaces.
• Identify and resolve structural, thermal, and mechanical performance issues.

3. Prototype Development and Hardware Integration

• Take mechanical designs from concept through fabrication, assembly, integration, and verification.
• Work directly with machinists, engineering technicians, and assembly personnel to develop physical hardware.
• Support CNC machining, additive manufacturing, precision fabrication, and prototype production.
• Evaluate fit, tolerances, alignment, accessibility, and assembly sequence.
• Resolve mechanical interference, packaging constraints, and integration challenges.
• Incorporate prototype build feedback into improved design revisions.

4. Testing, Validation, and Troubleshooting

• Develop and execute mechanical test plans and design-verification procedures.
• Support laboratory testing of integrated laser, photonics, and electro-optical systems.
• Evaluate mechanical integrity, thermal performance, dimensional accuracy, and stability.
• Analyze test results, identify root causes of failures, and implement corrective actions.
• Document test procedures, results, deviations, and engineering recommendations.

5. Manufacturing Support and Continuous Improvement

• Apply design-for-manufacturing and design-for-assembly principles to improve cost, quality, and production efficiency.
• Partner with manufacturing personnel to resolve fabrication and assembly problems.
• Develop assembly procedures, inspection requirements, and supporting technical documentation.
• Improve component standardization, tooling, fixtures, tolerances, and production repeatability.
• Support transition from engineering prototypes to production-ready hardware.
• Identify opportunities to improve reliability, manufacturability, product performance, and lifecycle cost.

6. Cross-Functional Collaboration

• Coordinate with optical, electrical, RF, systems, test, manufacturing, and quality engineering teams.
• Resolve multidisciplinary design conflicts and coordinate mechanical interfaces.
• Provide technical guidance to associate engineers, technicians, and assembly personnel.
• Participate in design reviews, project planning, and production-readiness activities.
• Communicate project status, technical risks, and schedule concerns to engineering leadership.

Required Qualifications

• Bachelor's degree in Mechanical Engineering or a closely related discipline.
• Typically three or more years of mechanical design, product development, or manufacturing engineering experience; equivalent demonstrated capability may be considered.
• Proficiency in 3D CAD modeling and engineering drawings, preferably SolidWorks.
• Strong understanding of mechanical design, statics, dynamics, materials science, heat transfer, and mechanics of materials.
• Experience with tolerance analysis, material selection, fasteners, and manufacturing processes.
• Ability to develop complete engineering drawing packages and bills of materials.
• Demonstrated ability to troubleshoot mechanical problems and translate test findings into design improvements.
• Experience working directly with machinists, technicians, suppliers, or manufacturing personnel.
• Strong analytical, technical writing, documentation, and communication skills.

Preferred Qualifications

• Experience with lasers, photonics, fiber-optic systems, optomechanics, or scientific instrumentation.
• Experience designing precision optical mounts, alignment structures, enclosures, and mechanical interfaces.
• Familiarity with high-power laser thermal management and electronic cooling.
• Experience with FEA, thermal simulation, CNC machining, additive manufacturing, and design for manufacturability.
• Knowledge of vibration, shock, environmental, and reliability testing.
• Familiarity with engineering change control, configuration management, and formal quality systems.
• Experience supporting aerospace, defense, semiconductor, or other high-reliability products.

Core Competencies

• Strong mechanical engineering fundamentals and sound technical judgment.
• Practical, hands-on problem-solving and hardware development capabilities.
• Ownership of designs and accountability for engineering deliverables.
• Precision, attention to detail, and disciplined documentation.
• Ability to balance technical performance, cost, manufacturability, and schedule.
• Effective communication and collaboration across engineering and manufacturing disciplines.
• Initiative, independent decision-making, and commitment to continuous improvement.

Measures of Success

• Quality, accuracy, and completeness of engineering designs and drawing packages.
• Timely completion of assigned engineering deliverables.
• Successful prototype integration and verification against requirements.
• Reduction in mechanical defects, assembly issues, and engineering rework.
• Effective resolution of thermal, structural, packaging, and manufacturing challenges.
• Improved manufacturability, reliability, and production readiness.
• Effective cross-functional collaboration and ownership of assigned projects.