Senior Mechanical Engineer I

ICON is seeking a Senior Mechanical Engineer I to drive the design, analysis, and implementation of critical mechanical subsystems for our next generation Titan 3D printing construction system. As a Mechanical Engineer at ICON you will own major design efforts, perform detailed engineering analysis, and be responsible for the full lifecycle of components from concept through final production. If you are passionate about solving complex, large-scale problems and seeing your designs deployed in the field, this role is for you. This is a full-time, onsite role is based at ICON’s Austin, TX HQ campus.

RESPONSIBILITIES

• Direct the application of existing principles and guide the development of new ideas for complex mechanical assemblies, systems, and specialized tooling for large-format robotic 3D printing construction equipment.

• Perform detailed engineering analyses (structural, thermal, and kinematic) using foundational hand calculations and advanced computational modeling (FEA/CFD) to evaluate stress, deflection, fatigue, thermal performance, and dynamic system behavior.

• Generate comprehensive engineering documentation, including 3D CAD models, detailed 2D drawings per ASME Y14.5 standards, and accurate Bills of Materials (BOMs).

• Lead cross-functional design reviews (DRs), incorporating feedback from industrial design, manufacturing, reliability, software, and field operations teams, while understanding the interrelationships of different disciplines.

• Drive the selection and qualification of commercial off-the-shelf (COTS) components, as well as collaborating with manufacturing and supply chain teams to ensure optimized design for manufacturability (DFM) and cost-effectiveness.

• Collaborate with manufacturing and supply chain teams to ensure designs are optimized for fabrication and cost-effectiveness.

• Network with key contacts outside your own area of expertise and adapt your communication style to use persuasion in delivering messages that relate to the wider audiences.

• Serves as a subject matter expert in mechanical design matters, frequently advising others on complex matters to positively influence product design decisions to drive impactful results for the business.

• Collaborate closely with Prototype Technicians and Manufacturing teams during the build phase to troubleshoot assembly issues and rapidly implement design updates.

• Develop and execute rigorous verification and validation plans (V&V) to ensure designs meet all functional, performance, and reliability requirements.

• Identify risks and drive mitigation strategies throughout the design process, utilizing tools like Failure Modes and Effects Analysis (FMEA).

• Provide hands-on support for field deployment and root cause analysis of mechanical failures in operational and prototype systems.

• Manage and control engineering documentation, including drawings, models, and Bills of Materials (BOMs), within the Product Data/Lifecycle Management (PDM/PLM) system.

• Review and check drawings created by other team members for accuracy, completeness, and adherence to established drafting standards.

• Mentor junior engineers and contribute to a culture of technical excellence and continuous improvement

• Perform other related duties as assigned to support the company's goals and objectives.

MINIMUM QUALIFICATIONS

• BS/MS in Mechanical Engineering (or similar relevant discipline).

• 8+ years of experience in hands-on mechanical design and product development, preferably involving robotics, automation, heavy equipment, or large machinery.

PREFERRED SKILLS AND EXPERIENCE

• Demonstrated expertise in designing and analyzing complex systems, including drive trains, gearboxes, linear motion, structural frames, and fluid handling systems. 

• Advanced proficiency in a major 3D CAD software (SolidWorks Preferred) and experience utilizing PDM/PLM systems (e.g. SolidWorks PDM, Windchill, Duro). 

• Proven experience performing or managing structural FEA models and thermal CFD models (e.g. SolidWorks Simulation, Ansys).

• Strong knowledge of Geometric Dimensioning and Tolerancing (GD&T) and its practical application in engineering documentation. 

• Advanced experience with various material selection and fabrication methods, including welding, machining, casting, sheet metal, CNC machining, and 3D printing. 

• Familiarity with industrial sensors, controls, and basic electrical/pneumatic integration. 

• Experience working in a rapid prototyping environment, bridging the gap between R&D and Serial Production. 

• Excellent attention to detail and ability to maintain consistent documentation standards across large assemblies.

• Experience designing, integrating, and troubleshooting fluid/hydraulic systems, and/or designing hardware for prolonged use in dusty, dirty, or harsh outdoor environments.

• Experience documenting technical data packages (TDP) within an established PDM/PLM system to support manufacturing scalability.

PHYSICAL/ENVIRONMENTAL REQUIREMENTS

• Must be able to lift 50 pounds occasionally.

• Must be able to work comfortably in an office and engineering shop/lab environment.

• Occasional travel (less than 5%) may be required to support supplier or manufacturing needs.