Design Engineer at RusselSmith Group

Job Summary

• The Design Engineer is responsible for leading additive manufacturing projects from concept to completion.
• This role focuses on optimizing additive processes, integrating advanced technologies, and ensuring compliance with industry standards.
• The successful candidate will collaborate across design, materials, and production teams to deliver high-quality, efficient, and reliable engineering solutions.

Responsibilities

• Lead additive manufacturing projects from initiation through planning, execution, monitoring, and final documentation.
• Optimize additive manufacturing processes to improve efficiency, quality, repeatability, and reliability.
• Research, evaluate, and implement new additive manufacturing technologies, materials, and equipment.
• Ensure full compliance with applicable industry standards, regulations, and quality requirements in additive manufacturing operations.
• Collaborate with design, materials, and production teams to ensure seamless product integration and manufacturability.
• Train, mentor, and provide technical guidance to junior engineers and technicians.
• Drive continuous improvement initiatives in additive processes, workflows, and operational performance.
• Develop, document, and maintain Standard Operating Procedures (SOPs), technical instructions, and engineering specifications.
• Identify process and equipment risks; implement mitigation strategies to ensure operational safety and performance.
• Apply quality assurance methodologies including Statistical Process Control (SPC) and Failure Mode and Effects Analysis (FMEA).
• Support reverse engineering, 3D modeling, and product development activities.
• Analyze technical data and resolve complex engineering challenges with data-driven solutions.
• Lead cross-functional teams to successfully deliver projects within scope and timelines.

Requirements

• Bachelor’s Degree in Mechanical Engineering, Mechatronics, Robotics, or Automation Engineering.
• Minimum of 5+ years experience in Reverse Engineering, 3D Modeling, and Product Development.
• Maintenance and Operations experience is an added advantage.
• Expert proficiency in CAD software (SolidWorks, Autodesk Fusion 360).
• Strong understanding of design principles, metrology parameters, and dimensional control.
• Hands-on experience with 3D printers, laser systems, and powder handling processes.
• Proven experience applying quality assurance tools such as SPC and FMEA.
• Strong analytical and strategic thinking skills with a data-driven approach to decision-making.
• Excellent verbal and written communication skills for both technical and non-technical audiences.
• Ability to thrive in fast-paced, collaborative environments while adapting to changing priorities.
• High attention to detail with a strong commitment to quality outputs.
• Demonstrated passion for continuous learning and staying updated on additive manufacturing trends and best practices.