R&D Mechanical Engineer

Research and Development Engineer – Mechanical Design & FEA | Highway Safety Products

About Us:
We design and manufacture highway safety products, including guardrails and crash cushions, engineered for controlled failure. Our team thrives on innovation, hands-on problem solving, and real-world testing at our dedicated crash test site. We value candidates who grew up on a farm, work on their own vehicles, or have a hands-on mechanical background.

Role Overview:
We are seeking a talented R&D Engineer to drive mechanical design and testing for new and modified safety products. You will plan, design, test, and document projects from concept through prototype to final production-ready designs, collaborating across Engineering, Manufacturing, Sales, and Marketing. Projects typically last 1–3 years and offer true R&D opportunities.

Key Responsibilities:

• Lead design, FEA analysis, prototype development, and testing for highway safety products.
• Ensure timely completion of projects through all R&D phases.
• Develop test matrices, perform cost analysis, and recommend manufacturing processes.
• Analyze product failures and implement controlled-failure designs.
• Prepare technical reports, presentations, and final design documentation.
• Collaborate closely with cross-functional teams.
• Occasionally assist with fabrication, assembly, and outdoor crash testing.

Required Qualifications:

• Bachelor's Degree in Mechanical, Civil, or related Engineering field. Master's considered with strong project experience.
• Minimum 3 years of R&D or mechanical design experience (or equivalent internships/projects).
• Strong mechanical design skills (Inventor, SolidWorks, or other 3D CAD).
• FEA experience (LS-DYNA preferred).
• Manufacturing experience and knowledge of steel products.
• Strong problem-solving, communication, and presentation skills.
• Self-starter with the ability to work independently or in a team.

Preferred Qualifications:

• Design for welding and multiple materials (metals, plastics).
• Patent design experience.

Work Environment:

• Office-based with some work in the fabrication shop and outdoor crash testing.
• Collaborative, cross-departmental team environment.
• May require extended hours and limited travel.

Benefits:

• Medical, Dental, Vision
• PTO
• 401(k) with company match
• Employee Assistance Program (EAP)