Senior Mechanical Design Engineer - ROUSH
Confirmed on the employer's own hiring board on Oct 21, 2026. First seen by Alion on Oct 13, 2026.
We work alongside the best and brightest to do incredibly cool things you wouldn't believe. At Roush, you're part of building the future. Are you someone that has a passion for providing innovated solutions to complex challenges? Do you want to work someplace where creativity and new ideas are encouraged? If so, then keep reading.
We fuse technology and engineering to provide product development solutions to customers in a diverse range of industries. Widely recognized for providing engineering, testing, prototype, and manufacturing services to the transportation industry, Roush also provides significant support to the aerospace, defense and theme park industries. With over 2,400 employees in facilities throughout the United States, Europe, Asia, and South America, our unique combination of creativity and tenacity activates big ideas on a global stage.
The Senior Mechanical Design Engineer is a broad role that requires working on a variety of engineering programs. The role works on projects for large and small customers to meet customer timelines. The Senior Mechanical Design Engineer works in a team environment to understand each customer’s unique needs and mentors and oversees team members’ technical deliverables to ensure Roush and customer standards are met. This position is located in Allen Park, MI
As a Senior Mechanical Design Engineer, you will:
- Develop and maintain 3D CAD models of complex mechanical systems, including parts, large assemblies, mechanisms, and integrated subsystems, utilizing robust parametric modeling practices with clear design intent to support iteration, reuse, and product evolution
- Build, manage, and validate large and configurable assemblies by performing interference checks, motion and fit analyses, and maintaining CAD data within a controlled, revision-managed, cross-functional environment
- Create and refine solid and surface models to meet functional, aesthetic, and manufacturability requirements, incorporating DFM/DFA principles directly into design geometry
- Translate customer needs into clear design requirements and feasible mechanical concepts, evolving designs from concept through prototype and supporting hardware development including testing all in a hands-on environment
- Produce accurate and complete 2D manufacturing drawings from 3D models, including GD&T, tolerancing, and industry-standard documentation to support fabrication and inspection
- Leverage CAD models to support engineering analysis, prototyping, testing, and supplier collaboration, including the use of Computer-Aided Engineering (CAE) tools to analytically validate and refine designs
- Provide technical leadership through mentoring, design reviews, and enforcement of modeling standards and best practices, offering guidance and coaching to team members
- Communicate design status, risks, and progress effectively through internal documentation and external customer reporting, while working hands-on in a mechanical development environment
To be considered for as a Senior Mechanical Design Engineer, you will need:
- Bachelor’s degree in Mechanical Engineering or equivalent
- Minimum 4 years of experience in automotive, aerospace, or related industry experience
- Experience with DFMEA, DVP&R, DFM, DFA and FEA
- Advanced knowledge of mechanical systems such as; kinematics and motion analysis, multi-degree-of-freedom linkages, hinge and latch mechanisms, cam and follower systems, gear trains, spring and damping mechanisms
- Hands-on troubleshooting and problem-solving skills
- Ability to work on multiple programs simultaneously
- Excellent computer skills including Microsoft Office Suite
- Strong verbal and written communication skills
- Ability to perform effectively in a team environment
A successful Senior Mechanical Design Engineer may also have:
- Master’s Degree in Mechanical Engineering or equivalent
- Simulation experience (FEA, physics-based modeling or similar)
- Hands-on ICE, hybrid and/or electric vehicle development experience
- Design and release experience within a PLM
Our full-time benefits include: medical, dental, vision, life insurance, earned sick time, STD, LTD, 401K, tuition reimbursement, paid vacation, paid holidays, and more.
If you share our passion for providing innovative solutions to complex challenges, we want you on our team.
Please visit our careers page and apply by clicking on this link: https://jobs.roush.com/us/en /
Visit our website: www.roush.com
Like us on Facebook: www.facebook.com/RoushCareers
Roush is an EO employer - Veterans/Disabled and other protected categories
If you need a reasonable accommodation for our employment application process due to disability, please contact Roush Talent Acquisition at (734) 779-7087.