Senior Mechanical Designer – Product Design (Sydney)

About the role

We are seeking a senior mechanical designer to lead end‑to‑end product development for physical hardware that reaches real users. You will own the mechanical design process from concept through to production release, working closely with cross‑functional teams in a Sydney‑based engineering environment.

Key responsibilities

• Lead mechanical design across concept, detailed design, prototyping, validation and production release.
• Create high‑quality 3D models, assemblies and detailed GD&T drawings.
• Drive DFM and DFA discussions with internal teams and external manufacturers, both local and offshore.
• Select appropriate materials and processes (plastics, metals, elastomers) based on function, cost and manufacturability.
• Collaborate with electronics, industrial design, firmware and supply‑chain teams to resolve integration challenges early.
• Conduct design reviews, FMEA and risk assessments.
• Support or lead prototype builds, test plans and failure analysis.
• Mentor junior engineers and review their outputs.
• Work with procurement and suppliers during tooling and first‑article stages to ensure design intent is maintained.

Required profile

• 7+ years of mechanical engineering experience in product development or NPD.
• Strong CAD proficiency (SolidWorks, CATIA, Creo or equivalent) with clean models and manufacturable drawings.
• Hands‑on experience with injection moulding, sheet metal, die casting, CNC machining and surface finishing.
• Solid understanding of tolerance analysis and GD&T in practice.
• Proven track record of shipping physical products and managing DFM, tooling and first‑article inspection with Asian or domestic supply chains.
• Engineering degree in Mechanical, Mechatronic or a related discipline.

Required skills

• SolidWorks, CATIA, Creo (CAD)
• GD&T and tolerance analysis
• Design for Manufacture (DFM) and Design for Assembly (DFA)
• Injection moulding, sheet metal fabrication, die casting, CNC machining, surface finishing
• Material selection (plastics, metals, elastomers)
• FMEA and risk assessment
• Prototype testing and failure analysis
• First‑article inspection and tooling coordination
• Supply‑chain management with overseas manufacturers
• Simulation tools (FEA) – optional