Sr. Project Design Engineer
Confirmed on the employer's own hiring board on Oct 11, 2026. First seen by Alion on Oct 6, 2026. Ralliant scores A on the Alion truth index.
Purpose of Position:
The Senior Project Design Engineer leads the detailed design and realization of complex products and product changes, ensuring solutions are fully defined, manufacturable, configurable, and ready for production. This role applies advanced technical judgment to resolve difficult design and realization challenges, guides others through complex design decisions, and contributes deep practitioner expertise to the development of design standards and practices.
Essential Functions:
- Lead complex product design and realization from concept handoff through production release, establishing a practical technical approach when requirements, constraints, or implementation paths are not fully defined.
- Apply advanced mechanical design and DFx expertise to balance product performance, reliability, materials, tolerances, manufacturability, assembly, inspection, cost, and lifecycle requirements.
- Develop and release complete product definitions using SolidWorks, including complex models, assemblies, drawings, configurations, tolerance analyses, bills of material, and supporting manufacturing documentation.
- Lead technically demanding engineering changes, product configurations, VAVE initiatives, and production improvements, resolving underlying technical problems and ensuring solutions are fully implemented.
- Lead technical reviews and provide peer guidance on difficult design and realization work, challenging assumptions, identifying downstream risks, and escalating decisions that require broader technical or management authority.
- Serve as a contributory author of design standards and practices, applying deep expertise in DFx, CAD, drafting, tolerance definition, product configuration, and manufacturing processes to develop practical technical guidance in partnership with Engineering Management and Engineering Systems.
Critical Success Factors:
- Delivers Complex Designs Ready for Production: Converts difficult or incomplete inputs into robust, manufacturable, and fully defined product solutions that achieve performance, quality, cost, and schedule objectives with minimal downstream rework.
- Elevates Design Execution Through Technical Expertise: Improves engineering decisions, guides others through difficult applications, and translates hands-on experience into practical contributions to design standards and practices.
Education & Experience Required:
Bachelor’s degree in Mechanical Engineering or a related engineering discipline. Equivalent education and directly relevant engineering experience may be considered.
7+ years of experience in mechanical design, electromechanical product design, product realization, or sustaining engineering within a manufacturing environment. Experience with industrial sensors, fluid handling systems, or similar engineered products is preferred.
Demonstrated success leading complex design and product-realization work through complete production release, including work involving incomplete requirements, competing constraints, or significant downstream consequences.
Advanced proficiency with SolidWorks, including complex assemblies, detailed drawings, configurations, design tables, and tolerance analysis. Certified SolidWorks Professional or equivalent demonstrated proficiency is highly desirable.
Experience working across CAD/PDM, ERP, product configuration, and engineering-change environments, with an understanding of how product-definition decisions affect downstream execution.
Strong knowledge of DFx and manufacturing processes such as machining, injection molding, casting, joining, and assembly, with demonstrated ability to balance manufacturability, performance, reliability, quality, and cost.
Experience resolving difficult design or production problems, providing technical guidance to other engineers, and contributing expert content to design standards or practices.