Senior Mechanical Engineer

About Aegis Sortation

At Aegis, our purpose is clear: to create raving fans through expert innovation in intralogistics. Our team combines innovative thinking with deep industry expertise to deliver solutions for projects of all sizes, throughputs, and complexities.

Aegis Sortation is a leader in the intralogistics technology and innovation space. Our expertise spans E-Commerce, Freight and Parcel, and Warehouse and Distribution. As a prime integrator, we have a team capable of conceptualizing and laying out complex systems, and completing detailed design engineering, procurement, and field installation across various project platforms. Our commitment to integrating excellence throughout the project life cycle sets us apart, delivering automation solutions to businesses ranging from local service providers to international logistics giants.

Overview:

The Senior Mechanical Engineer - Product Design drives complex mechanical design for high-performance material handling systems (conveyors, sorters, and autonomous parcel handling equipment) while leading testing, data acquisition, and performance analysis to de-risk Stage Gate deliverables. You will balance deep technical ownership with mentoring Level 1–2 team members and advancing our BHAG of fully autonomous facilities by 2030. You will also own the design-to-validation loop for systems that directly improve uptime, throughput, and package integrity in demanding parcel environments.

Primary Responsibilities:

• Create complex mechanical designs (assemblies, subsystems, and components) from specifications, napkin sketches, or customer requirements using SolidWorks.
• Perform advanced stress, strain, deflection, and dynamic analyses using SolidWorks Simulation; validate designs against parcel handling performance requirements.
• Apply design of experiments and root cause analysis to machine design and development, including during simulation. Work with a cross-functional team to ensure test plans have sufficient instrumentation for data analysis with statistical confidence. Clearly communicate data-driven, actionable recommendations to stakeholders.
• Lead or independently perform full system design reviews covering mechanical integrity, integration, manufacturability, safety, serviceability, and alignment to Stage Gate exit criteria.
• Own user stories and lead cross-functional teams (mechanical, electrical, controls, manufacturing) via Microsoft Teams to meet Stage Gate milestones.
• Accurately estimate effort, create timelines, and drive internal/external resources to schedule.
• Mentor Level 1 and 2 engineers on design best practices, DFMEA, Safety Risk Analysis, and testing rigor.
• Contribute to backlog refinement, sprint planning, and retrospectives while reinforcing core values and collaborative culture.

Requirements

• Minimum 10 years of progressive mechanical design experience in industrial automation, custom machinery, or material handling systems.
• Preferred: Direct experience with freight/parcel, high-volume logistics, or distribution equipment (conveyors, sorters, automated bagging, or similar high-throughput systems).
• Bachelor’s degree in Mechanical Engineering required; Master’s preferred.
• Proven track record delivering tested, production-ready designs that exceed customer performance requirements (throughput, jam rates, package integrity, energy consumption, MTBF).
• Experience in freight, parcel, or high-throughput logistics environments.
• Hands-on work with conveyor, sortation, or automated packaging/bagging systems.
• Familiarity with high-uptime targets, MTBF analysis, or field performance validation against real parcel mixes (smalls, irregulars, polybags).
• Exposure to vision-guided or adaptive conveyance technologies.
• Experience leading or contributing to full system design reviews.