Senior Mechanical Design Engineer at Solara Solutions, LLC – Morrisville, North Carolina

Senior Mechanical Design Engineer

Join us at the cutting edge of industrial automation, where your mechanical engineering expertise will power the next generation of intelligent, high‑performance equipment. As a Senior Mechanical Engineer, you will lead the design, integration, and delivery of complex automation systems - blending hands‑on mechanical design with project leadership and cross‑disciplinary collaboration to turn ambitious engineering challenges into real‑world capability.

Qualifications and Skills:

Required

• BS/MS in Mechanical Engineering
• 8+ years mechanical design experience; 5+ years at a robotic systems integrator designing custom machinery
• Proficient in SolidWorks 3D CAD/PDM; experience applying GD&T
• Experience sizing actuators/servos/sensors/pneumatics; robotic cell design (reach/cycle analysis, safety, risk assessment)
• Machining/fabrication knowledge; managing vendors for machined parts, welding, sheet metal and finishing processes (selection, communication, receiving quality)

Desired

• Machine vision and 3D sensing integration; complex applications (vision-guided, dispensing, finishing)
• Fanuc and Universal Robots system design; simulation software and programming

Job Responsibilities:

Sales & Concept Support

• Partner with sales on customer visits; review RFQ requirements and parts/models/drawings
• Deliver presentations/POCs and recommend solutions aligned to technical and budget needs
• Support cost estimates, quotes, and proposals; translate requirements into engineered solutions and adapt standard offerings as needed
• Serve as the primary technical contact during sales and hand off requirements to project teams after order placement

Mechanical Design & Development

• Design complex pneumatic/electromechanical machinery and robotic cells in SolidWorks
• Integrate robots, EOAT, feeders, and material handling; lead internal/external design reviews
• Create 3D models/assemblies and manufacturing-ready detail/assembly drawings

Continuous Improvement

• Identify opportunities to improve performance, reduce costs, and enhance system reliability.

Systems Integration

• Collaborate with controls, electrical, and software engineers to integrate robotics (articulated arms, SCARA, Delta, cobots) into automated production lines.

Project Management

• Lead projects from concept through FAT/SAT and installation; manage scope, schedule, and budget with teams, suppliers, and clients

Vendor & Supply Chain Coordination

• Source and qualify components, manage supplier relationships, and oversee outsourced fabrication/assembly.

Compliance & Safety

• Ensure OSHA/ANSI/CE/ISO safety compliance by performing risk assessments

Build, Testing & Debugging

• Oversee equipment build and test/debug; lead assemblers and drive cross-team fixes across mechanical, electrical, and controls

FAT/SAT & Installation

• Develop/execute/document FAT/SAT protocols; lead on-site SAT to resolve deviations and secure acceptance
• Plan/coordinate installation and commissioning (mechanical, electrical, controls) to meet milestones and mitigate risk

Documentation

• Write equipment documentation (test plans, user manuals, maintenance procedures)

This position is on-site, at our office located in Raleigh, NC. Remote or hybrid work options are not available, and relocation expenses are not covered.

About AAE North America

AAE North America is a family-owned technology company headquartered in the Netherlands, recognized for innovation, precision, and a people-first approach. Based in Morrisville, NC—minutes from Research Triangle Park—we deliver groundbreaking high-tech solutions within a family-like culture. We don’t build standard machines; we develop advanced modules, systems, and complete automation solutions capable of producing up to 350 million products per year, including precision components for revolutionary medical and semiconductor applications. Designs and manufacturing take place in Raleigh, NC, USA, and at our headquarters in the Netherlands, and we deliver solutions worldwide—so you’ll work with cutting-edge technology that’s constantly evolving. Our success comes from the drive, creativity, and pride of our team—at AAE, you’re not just an employee; you’re part of something great.