About this role
About the Role Senior Design Engineer for head protection responsible for developing production-ready innovations that enhance safety, comfort, and performance. You will lead design maturation by setting performance targets, generating and analyzing data (tests + models), and reducing technical risk to ensure confident launches across early exploration through transfer to production.
What You'll Do
- Develop innovative solutions with industry-leading safety performance in head protection products.
- Define performance objectives and validation strategies; develop and execute test plans for functional, durability, and environmental requirements.
- Instrument prototypes/fixtures for high-fidelity data capture; analyze results with DOE, regression, and reliability models to quantify trade-offs.
- Collaborate with simulation engineers to develop FEA/CFD/thermal models to lab/field data; update models based on findings; drive root-cause analysis and reliability growth.
- Utilize high speed video, Python tools, and other advanced data analysis techniques to synthesize test results into actionable findings.
- Partner with manufacturing and suppliers on process capability, materials, and tooling; feed cost/quality/takt insights into design iterations and risk mitigation.
- Plan and execute prototyping—from proof-of-feasibility through production-representative builds—and capture lessons learned to inform downstream development.
- Document technical decisions, assumptions, and test outcomes in clear reports; present findings and recommendations to cross-functional stakeholders.
- Cultivate curiosity toward AI: proactively explore and run small proofs-of-concept where machine learning, generative design, and intelligent automation can improve analysis, prototyping, and test design.
- Mentor engineers in test design, analysis, and modeling; foster first-principles thinking and measurable outcomes.
- Typical Advanced Engineering Workflow: Discovery → Definition → Exploration & Prototyping → Validation → Transfer to Production.
What We're Looking For
- Bachelor’s degree in Mechanical, Product, or Material Engineering (or related); advanced degree a plus.
- 2+ years experience with energy absorption technologies and/or head protection products.
- 5+ years of product development experience in automotive, industrial, consumer/durable goods, or adjacent industries.
- Demonstrated expertise in test planning/execution, data analysis, and modeling/simulation (FEA/CFD/thermal).
- Proficiency in CAD; experience with DFMA, prototyping methods, and supplier collaboration.
- Hands-on with instrumentation/DAQ and statistical tools (e.g., JMP/Minitab); familiarity with reliability methods (e.g., accelerated life testing, Weibull).
- Excellent communication skills—able to synthesize complex data into clear design recommendations; strong cross-functional collaboration.
- Practical experience applying ML/AI to guide mechanical design and integrate proven tools into standard engineering workflows.
- Self-starter comfortable learning beyond core discipline; able to manage ambiguous design tasks.
- Willingness to travel ~10% (domestic/international).
Nice to Have
- Advanced degree is a plus.
- Experience applying ML/AI to design processes or generative design.
Compensation & Benefits
- Salary and benefits not disclosed in the posting.
- Milwaukee Tool is an equal opportunity employer.