Design & Development Engineer

About Sperry:

Sperry Rail is on a mission-critical journey to revolutionize the Rail Flaw Detection industry. Through the continuous development of cutting-edge diagnostic technologies and AI-assisted analysis, we are transforming railway safety worldwide. Our global engineering teams work collaboratively to develop step-change technologies that define Sperry as the unparalleled market leader.

For nearly a century, we have repeatedly modernized and improved rail diagnostics through our relentless pursuit of improvement. Determined is an understatement. We are obsessed with advancing science and raising the bar on what’s possible with our ever-improving suite of products and service offerings.

Emboldened through the shared values of honesty, accountability, passion, integrity, and teamwork, we are driven by the challenge and bridging concepts with fruition. Each technologist entering Sperry imprints themselves into our brand and further galvanizes a culture of innovation and advancement. Allow us to be clear, Thought Leaders are welcome!

We are agile and hungry and invite those with similar passions to join us in challenging the status quo and bringing new ideas to the market. Fast-paced, high-touch with a distinct sense of purpose. We offer more than a job; we offer an opportunity to be part of something different.

Job Description: Design & Development Engineer

Position Summary

The Design & Development Engineer is a core member of Sperry Rail's Design & Development Engineering group, responsible for the creation, development, and validation of next-generation rail inspection platforms and the systems that power them. Working across new platform development, technology advancement, and engineering change management, this role requires both independent technical execution and strong cross-functional collaboration. Engineers in this group own their work from concept through design release - producing not only functional designs but complete, production-ready technical data packages that meet engineering, production, and maintenance requirements.

This position is suited for an Engineer with demonstrated experience in mechanical systems who is ready to take ownership of projects, drive design decisions, and contribute to the long-term technical direction of the business.

Key Responsibilities

Platform & Product Development

• Design and develop mechanical, electrical, or systems-level hardware for new and existing rail inspection platforms (Hi-Rail, Railbound, Pedestrian/HT, ATSProLite/ATSPro).
• Produce complete technical data packages (TDPs) including 3D CAD models, 2D manufacturing drawings, electrical schematics, BOMs, and interface control documents - suitable for production and maintenance use.
• Apply DFM, DFA, and DFI principles throughout the design process to ensure producibility, ease of assembly, and maintainability.
• Develop and maintain multi-level Bills of Materials in Sage X3 ERP and PDM systems, ensuring accuracy and traceability across design revisions.
• Participate in and lead cross-functional design reviews, incorporating feedback from Production, Quality, Supply Chain, and field operations.
• Own designs through the full development lifecycle, including design reviews, risk identification and mitigation, qualification testing, and design release.

Engineering Change & Problem Solving

• Lead or support root cause and corrective action (RCCA) efforts for design-related field issues, applying structured problem-solving methodology.
• Evaluate and implement engineering changes driven by field performance data, supplier constraints, obsolescence, or customer requirements.
• Document and communicate design changes clearly and completely, including impact assessments for Production, Maintenance, and the existing fleet.

Collaboration & Process Adherence

• Work closely with Production Engineering to ensure smooth transition from design to build, resolving manufacturing and assembly challenges early.
• Coordinate with the Technology/R&D group to incorporate new sensor technology, calibration requirements, and inspection capability improvements into platform designs.
• Follow established development processes including stage-gate reviews, requirements management, and verification and validation planning.
• Mentor team members as appropriate to role level, supporting the development of junior engineering talent.

Required Qualifications & Skills

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Systems Engineering, or a closely related field.
• 5+ years of professional engineering experience in product development and/or platform design.
• Demonstrated ability to produce complete engineering documentation including drawings, BOMs, and specifications suitable for manufacturing and maintenance use.
• Experience with 3D CAD software (SolidWorks preferred) and PDM/PLM systems.
• Proficiency in GD&T and tolerance analysis.
• Strong problem-solving skills with experience applying structured root cause analysis methods.
• Effective written and verbal communication, including the ability to present technical information to cross-functional audiences.

Preferred Experience & Skills

• Experience in rail, transportation, defense, or other regulated industries where design documentation and process discipline are required.
• Familiarity with electromechanical system integration, including sensors, actuators, cables, and connectors.
• Exposure to ERP systems (Sage X3 or similar) for BOM and demand management.
• Experience with requirements management and verification planning (e.g., VCRM, traceability matrices).
• Background in new product introduction (NPI) or transition from engineering to production.

Work Environment

This position is based at our Shelton, CT facility. The role involves a mix of office and engineering design work with hands-on time in our production and lab areas. Travel may be required to support field validation activities, customer sites, supplier visits, or UK/NA program collaboration.