Principal Mechanical Engineer - Web Handling

Join the power movement as Principal Mechanical Engineer - Web Handling

We are looking for a Principal Mechanical Engineer specializing in Web Handling and Roll-to-Roll (R2R) systems to serve as the definitive company-wide technical authority for continuous material processing equipment. In this "First Chair" leadership role, you will shape the overall technical direction, architecture, and deployment of high-precision web transport systems operating in a variety of thermal environments.

You will lead the execution of highly complex, ambiguous cross-functional initiatives that directly impact our core R&D and manufacturing roadmap. Operating with complete independence, you will combine deep technical expertise in web dynamics and precision mechatronics, with strategic leadership establishing division-wide design standards, mitigating significant technical risks, and mentoring the engineering organization.

What you'll do:

• Shape R2R System Architecture: Serve as the chief architect for next-generation roll-to-roll equipment, dynamic tension systems, precision accumulators, and high-speed winders/unwinders
• Research Advanced Winding & Unwinding Technologies: Actively research, evaluate, and benchmark next-generation web handling, winding, and unwinding equipment and technologies to inform tool architecture and roadmap decisions
• Lead Cross-Functional Strategy: Translate complex scientific R&D objectives into actionable engineering architectures, bridging mechanical design, process physics, electrical hardware, and closed-loop controls across multiple project groups
• Master Web Dynamics & Technical Risk: Drive advanced dynamic modeling, web physics analysis, and experimental validation to resolve critical web defects (e.g., thermal buckling, lateral drift, scratching, or tension transients) in flexible metal substrates
• Establish Division Standards: Institutionalize company-wide engineering standards, design guidelines, and testing methodologies for web handling, precision roller design, bearing selection, and mechatronics
• Drive Process & Tool Innovation: Pioneer novel mechanical concepts, dynamic guiding schemes, and non-contact web transport modules operating inside temperature zones
• Independently Manage Risk: Identify, evaluate, and mitigate high-impact technical risks across major equipment initiatives, establishing contingency paths and robust design margins
• Direct Strategic Vendor Partnerships: Audit, qualify, and direct global suppliers and contract manufacturers for specialized R2R sub-assemblies, precision ground rollers, custom surface coatings, and drive components
• Organization-Wide Mentorship: Actively coach and mentor Staff, Senior, and Junior mechanical engineers, elevating technical rigor, design review standards, and professional development across the discipline.

What we’re looking for:

• Education: Master’s or PhD in Mechanical Engineering, Mechatronics, or a related field (or equivalent specialized industrial experience)
• Experience: 15+ years of proven track record as a recognized technical leader in the architectural design, scaling, and implementation of complex web handling, roll-to-roll (R2R), or converting equipment
• Deep Domain Expertise: Authoritative knowledge of web handling physics-closed-loop tension control, winder dynamics, lateral guiding, roller traction, nip mechanics, load cell integration, and substrate stress distribution
• Cross-Disciplinary Mastery: Demonstrated capability to integrate mechanical systems seamlessly with advanced motion controls, power electronics, and thermal management systems
• Proven Track Record in High-Stakes Tooling: Successful history of bringing first-of-a-kind continuous processing capital equipment from concept through commissioning and high-yield operational scale
• Influential Leadership: Demonstrated ability to drive technical consensus and lead multi-disciplinary teams without relying on formal line management authority

Bonus points for:

• CAD & Simulation Leadership: Advanced mastery of 3D CAD platforms (SolidWorks and/or NX) paired with expertise in multi-body dynamics, non-linear FEA, and finite-difference web simulations
• Brittle & High-Strength Substrate Transport: Specialized experience handling narrow metal tapes, high-strength alloys, or delicate multi-layer composite webs
• Advanced Motion & Control Loops: Deep familiarity with tuning multi-axis servo drives, dancer control algorithms, and adaptive tension loops

Must-have Requirements:

• Ability to occasionally lift up to 50 lbs
• Perform activities such as stooping, climbing, standing, or sitting for extended periods of time
• Dedication to safety to mitigate industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, and cryogenics
• Willingness to travel or work required nights/weekends/on-call occasionally