Overview
Senior Mechanical Designer Jobs in Sydney, New South Wales, Australia at ProFound People
Title: Senior Mechanical Designer
Company: ProFound People
Location: Sydney, New South Wales, Australia
Senior Mechanical Engineer – Product Design | Sydney
You're a well-rounded mechanical engineer who's as comfortable in the workshop pulling apart a prototype as you are at your desk resolving a tolerance stack-up. You've taken products from concept through to manufacture, you understand what it actually takes to ship hardware, and you bring both technical rigour and practical hands-on judgment to every stage of the process.
This is a senior role inside a Sydney-based engineering team working on physical products that reach real users. You'll own mechanical design end-to-end, from early concept through detailed design, prototyping, validation, and production release, and you'll be expected to lead, not just execute.
What you'll be doing
- Leading mechanical design across the full product development cycle – concept, detailed design, prototype, validation, and production release
- Producing high-quality 3D models, assemblies, and detailed drawings with full GD&T
- Driving DFM and DFA conversations with internal teams and external manufacturing partners, locally and offshore
- Owning material and process selection, plastics, metals, elastomers, matched to function, cost, and manufacturability
- Collaborating with cross-functional teams (electronics, industrial design, firmware, supply chain) to resolve integration challenges early
- Contributing to and leading design reviews, FMEA, and risk assessments
- Supporting or leading physical build and validation – prototype builds, test plans, failure analysis
- Potentially mentoring junior engineers and reviewing their outputs
- Working with procurement and suppliers during tooling and first-article stages to ensure design intent is maintained through to production
What you'll bring
- 7+ years of mechanical engineering experience in a product development or NPD environment
- Strong CAD proficiency (SolidWorks, CATIA, Creo, or equivalent) – you're fast, your models are clean, and your drawings can be manufactured from
- Hands-on experience across multiple manufacturing processes – injection moulding, sheet metal, die casting, CNC machined components, and surface finishing
- Solid understanding of tolerance analysis and GD&T in practice, not just on paper
- Experience managing products through DFM, tooling, and first-article inspection with Asian or domestic supply chains
- A track record of physical products you've shipped – portfolio or examples of your work are a strong advantage
- Engineering degree in Mechanical, Mechatronic, or a closely related discipline
Bonus points for
- Experience in a regulated or high-reliability product category (medical, defence, industrial, or similar)
- Exposure to simulation tools (FEA) for design validation
- Hands-on prototyping skills – you're comfortable in a workshop as well as at a desk
- Experience working with ID teams and translating aesthetic intent into manufacturable geometry
Apply here or send through your CV and portfolio to [email protected]
