Senior Mechanical Design Engineer

Job Summary: A Senior Mechanical Design Engineer (otherwise known as a Research & Development Engineer) at Barnhart is a highly skilled and experienced leader who collaborates with a team to design and produce cutting-edge load handling equipment for use in the heavy lift and heavy transport industry. This role involves spearheading design projects to optimize functionality, safety, efficiency, and value in the equipment used to perform specialized heavy lift and transport work. Senior R&D Engineers leverage their expertise to solve complex challenges, develop innovative equipment, and mentor the next generation of talented engineers. This position offers the unique opportunity to oversee projects from initial concept to final completion, providing a comprehensive and rewarding experience.

Job Requirements:

• Experience: 7+ years of qualifying experience designing mechanical and/or structural equipment for a similar industry with a proven track record of success.
• Certifications: Professional Engineer (PE) license preferred, OSHA 10
• Technical Proficiency: Extensive expertise in mechanical design, structural analysis, and finite element analysis (FEA) for developing and evaluating custom lifting and transport equipment. Demonstrated proficiency with cranes, hoists, hydraulic systems, winches, and rigging equipment, including detailed knowledge of load charts, operational constraints, and safety standards. Skilled in advanced lifting methods such as tandem lifts, heavy load skidding, and modular transport systems. Highly proficient in CAD software (e.g., SolidWorks, AutoCAD, Inventor) for precise design and modeling. Comprehensive knowledge of stress analysis, fatigue analysis, and failure modes, ensuring structural integrity under both dynamic and static loads. Experienced in performing hand calculations and utilizing various programs (e.g., ANSYS, Nastran, Abaqus, RISA-3D) for structural and mechanical evaluations. Strong understanding of materials used in heavy equipment, including steel grades, composites, and high-strength alloys. Adept at integrating mechanical, hydraulic, and electrical systems into cohesive, functional equipment designs. Thorough knowledge of industry standards and regulations, including OSHA, AISC, AWS, ASME B30 Series, ANSI, and ASCE-7, ensuring compliance and adherence to best practices. Proven ability to plan and conduct equipment testing, including load tests, structural validation, and prototype evaluations, with expertise in documenting test results and leveraging findings to optimize designs.
• Software Proficiency: Familiarity with engineering software (i.e. RISA-3D, Ansys Mechanical, Mathcad, MS Excel), as well as ERP systems, scheduling software, video conferencing platforms (WebEx, Zoom, Teams, etc.), and Microsoft Office Suite.
• Problem-Solving and Analytical Expertise: Ability to lead design reviews, troubleshoot performance issues, and implement iterative improvements. Strong analytical skills to address complex engineering challenges and devise innovative solutions. A demonstrated ability to think creatively while adhering to technical and operational constraints.
• Communication: Strong verbal and written communication skills with proven ability to work in cross-functional teams, liaise with clients and stakeholders, and mentor junior engineers in technical disciplines; proficient in preparing and presenting project reports, technical documentation, and equipment operating procedures.
• Project Management Skills: Strong leadership skills with experience in managing project budgets, schedules, and risks, while mentoring a team of engineers and technicians to ensure timely and cost-effective project completion.
• Physical Requirements: Willingness to travel to project sites as needed. Ability to work in a variety of environments, including outdoor and construction sites, and conduct on-site inspections, which may involve standing, walking, crawling, and climbing ladders or scaffolding.
• Fit for Duty: Must pass a drug test, fit for duty and background check.

Job Responsibilities:

• The Senior R&D Engineer leads the design and development of specialized load-handling equipment, ensuring alignment with project requirements and industry standards. The Research & Development process spans the entire project lifecycle and includes the following key phases:
  • Idea Phase: At Barnhart, we continually seek opportunities to improve and grow as an industry leader. Ideas often originate from field personnel, project managers, sales teams, operators, and senior leadership. The R&D team evaluates the viability of these ideas to determine whether they should be pursued further.
  • Concept Phase: During this phase, the team gathers key information and establishes preliminary design parameters. Early-stage CAD m