Mechanical Designer - Automation & Integration in Exton, Pennsylvania at SunSource

As a Mechanical Designer within the Integration team, you will serve as a key contributor to the design and development of custom automation systems. You will transform customer requirements, application details, and site conditions into fully engineered solutions, including system layouts, tooling, fixturing, and fabrication-ready documentation.

You will collaborate closely with engineering, controls, and project teams from concept through installation and final handoff. This role requires a strong focus on design quality, manufacturability, and clear documentation, along with the ability to communicate effectively with both internal teams and customers.

• Develop 3D models and detailed fabrication drawings for automation systems, tooling, fixtures, guarding, and structural assemblies using CAD software (e.g., SolidWorks)
• Design components and assemblies with consideration for manufacturability, cost, and durability (sheet metal, machined parts, welded structures, etc.)
• Create and maintain bills of materials (BOMs) to support sourcing and procurement
• Apply GD&T principles to ensure designs are manufacturable, inspectable, and repeatable
• Perform engineering analysis (e.g., FEA or hand calculations) to validate structural integrity and safety factors where applicable

• Develop full system and cell layouts, accounting for equipment footprint, operator interaction, maintenance access, and safety requirements
• Define and document tooling interfaces, mounting schemes, and changeover strategies
• Collaborate with controls and electrical teams on routing for cables, pneumatics, sensors, and I/O components
• Design for efficient assembly and installation, identifying opportunities to simplify field deployment

• Present design concepts, layouts, and models to internal stakeholders and customer teams for review and alignment
• Incorporate customer feedback, site constraints, and application requirements into design revisions
• Account for real-world conditions such as facility layout, floor loading, clearances, and existing equipment interfaces
• Support project handoff by delivering accurate and complete documentation packages (drawings, BOMs, manuals, and as-built updates)

• Contribute to the development and maintenance of reusable design standards, components, and libraries
• Follow and help improve internal design practices, templates, revision control, and file management processes
• Identify recurring design challenges and help implement standardized solutions to improve efficiency and consistency
• Support continuous improvement initiatives within the engineering and integration teams

• 3–5 years of mechanical design experience in automation, equipment design, or custom manufacturing environments
• Proven experience taking designs from concept through fabrication, assembly, and installation
• Experience designing tooling, fixtures, or custom mechanical systems
• Experience working in regulated or high-compliance industries prefered
• Associate’s or Bachelor’s degree in Mechanical Engineering, Mechanical Design, or equivalent experience prefered

• Strong proficiency in CAD software (SolidWorks preferred; AutoCAD or equivalent is a plus)
• Solid understanding of GD&T and creation of production-ready drawing packages
• Experience with common manufacturing processes: sheet metal, machining, welding, and additive manufacturing
• Familiarity with system layout considerations including access, safety, and maintainability
• Experience selecting and integrating off-the-shelf components (actuators, linear systems, sensors, etc.)
• Working knowledge of cable management, pneumatic routing, and general system integration practices
• Strong attention to detail and commitment to high-quality deliverables
• Collaborative and team-oriented with clear communication skills
• Ability to manage multiple projects and priorities effectively
• Practical, solutions-oriented mindset with a focus on execution
• CAD certification (e.g., SolidWorks)
• Experience with simulation or layout validation tools
• Background in automation applications such as assembly, material handling, machine tending, or inspection systems
• Familiarity with applicable safety standards (ANSI, ISO, OSHA, etc.)