Sr. Mechanical Engineer

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 innovative 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. 

We offer a full array of benefits to our full-time employees, including medical, dental, vision, life insurance, earned sick time, STD, LTD, 401K, tuition reimbursement, paid vacation, and paid holidays.

The Senior Mechanical Engineer is a senior-level engineering position responsible for leading the design, development, and release of complex systems or multiple sub-systems. This role serves as a subject matter expert, mentoring other engineers, and interfacing directly with customers to provide technical consulting and ensure engineering excellence. The Senior Mechanical Engineer is accountable for translating requirements into robust, manufacturable designs that meet performance, cost, and timing targets while aligning with company standards and industry regulations.              


As a Sr. Mechanical Engineer, you will:

• Own the complete design and release process for assigned systems, from concept through production release, ensuring compliance with budget and adherence to program milestones
• Perform packaging studies, integration work, and tolerance analyses to ensure design robustness
• Lead DFMEA, CAE, and DVP&R creation, ensuring validation plans are comprehensive and aligned with program needs
• Manage technical interfaces with suppliers, ensuring designs meet performance, cost, and timing objectives
• Support and lead resolution of issues identified during prototype builds, testing phases, and production launch
• Present designs, trade-off decisions, and risk mitigation strategies to customers, internal leadership, and executive review boards
• Mentor and coach Mechanical Engineer I and II staff, providing guidance in both technical execution and professional growth
• Responsible for reporting engineering and design status to the Program Manager and supporting program reviews with internal and external stakeholders

• Bachelor’s degree in mechanical engineering or similar
• Minimum of 4 years of engineering work experience in vehicle or mobility product engineering.
• Proven experience delivering designs that meet cost, performance, and manufacturability requirements
• Functional proficiency in CAD tools such as SolidWorks, NX, or CATIA, as well as GD&T and industry design standards
• Strong understanding of manufacturing processes and supply chain integration in the automotive or mobility sectors
• Demonstrated ability to take ownership of complex systems from concept through production launch
• Proven ability to lead cross-functional teams and resolve complex engineering challenges.
• Strong consulting skills, including the ability to lead client-facing technical discussions, recommend design strategies, and advise on risks and opportunities
• Excellent communication, leadership, and mentorship skills to assist in guiding engineering teams toward successful project outcomes
• Ability to balance creative design solutions with practical manufacturing constraints

• Experience in OEM, Tier-1 supplier, or engineering services environments
• Background in advanced manufacturing techniques, lightweight materials, or emerging technologies
• Experience in customer-facing engineering roles involving design consultation and solution development
• Familiarity with advanced CAE tools for structural, thermal, or dynamic analysis
• Experience with Design for Manufacturing (DFM) and Design for Assembly (DFA) methodologies
• Knowledge of vehicle development processes, including gateway reviews and milestone deliverables
• Experience working within APQP or similar product quality planning frameworks
• Background in managing design changes and engineering documentation in PLM systems
• Ability to apply lessons learned and best practices from previous programs to future de