Product Development Engineer

Product Development Engineer

Encore Automation - Company Overview

Encore Automation is a leader in the development, integration, and installation of automated finishing systems for manufacturing plants in the Automotive, Aerospace, and General Industries. Our team of more than 90 engineers, programmers, and project managers supports the full project lifecycle, including design, manufacturing, testing, installation, commissioning, service, and training. Our systems address automated surface preparation, coating application, material dispensing, and metrology processes.

Position Summary

The Product Development Engineer is a position focused on developing, testing, and commissioning new automated products and technical solutions involving machine vision, robotics, mechanical design, simulation, fluid dispensing, prototyping, and system validation. The engineer takes concepts from research and design through prototyping, testing, documentation, and implementation while working with internal teams, suppliers, and customers to deliver practical, reliable, and manufacturable solutions.

Key Responsibilities

New Product Development and Testing

• Research and evaluate technologies for new products and system improvements.
• Develop product concepts, prototypes, and proof-of-concept systems.
• Create test methods, test plans, and validation procedures for evaluating system performance, accuracy, and reliability.
• Conduct experiments; collect, organize, and analyze test data; and recommend design improvements based on results.
• Apply mathematical fundamentals, including statistics, trigonometry, and matrices, to engineering and data-analysis problems.
• Prepare technical reports, test documentation, procedures, engineering drawings, and bills of materials.
• Support rapid prototyping and fabrication using 3D printing, basic machining, assembly, and other development methods.

SMART System Development

• Develop camera-aiming methods, camera placement strategies, calibration procedures, and supporting process designs for machine vision applications.
• Support the development and integration of vision system technology and related robotic guidance solutions.
• Develop and perform accuracy and validation testing for robotic and vision-guided systems.
• Create mechanical and electrical system concepts, drawings, and bills of materials.
• Develop and test fluid-dispensing systems and related application processes.
• Support the development and improvement of automated film-cell applications.
• Operate and program industrial robots for development, testing, and process validation.
• Develop and evaluate robotic processes, tooling concepts, and application sequences.
• Collaborate with suppliers and technology partners to integrate robots, tooling, sensors, controls, and supporting equipment.

Simulation

• Prepare customer and engineering CAD models for simulation, including mesh modification, simplification, and data organization.
• Create camera simulations to evaluate field of view, coverage, camera placement, and system feasibility.
• Use simulation results to support system-design decisions and prepare clear technical presentations for customers and internal teams.

Mechanical and Systems Engineering

• Design robotic tooling, brackets, fixtures, and supporting mechanical components.
• Create 3D CAD models and detailed engineering drawings using design-for-manufacturing and design-for-assembly principles.
• Select and source components for prototype and production systems and maintain supporting bills of materials.
• Design and integrate photo eyes, sensors, electrical components, and related mounting hardware.
• Review designs for manufacturability, serviceability, accuracy, and reliability.

Commissioning and Troubleshooting

• Assemble and test prototype and production equipment.
• Support system installation and commissioning at internal and customer facilities.
• Collect and analyze performance data during testing and commissioning.
• Troubleshoot mechanical, electrical, robotic, software, and vision-system issues; identify root causes; and develop corrective actions.
• Document system settings, test and commissioning results, open issues, and recommended actions.

Basic Qualifications

• Bachelor's degree in mechanical engineering, mechatronics engineering, robotics engineering, electrical engineering, manufacturing engineering, or a related technical field.
• Approximately 3-7 years of relevant product development, automation, robotics, machine vision, or systems-engineering experience.
• Experience developing and testing new products, prototypes, or automated equipment.
• Proficiency with 3D CAD software, preferably SolidWorks.
• Experience creating engineering drawings and bills of materials.
• Hands-on experience with prototyping, assembly, testing, and troubleshooting.
• Experience collecting, organizing, and analyzing technical data.
• Understanding of test-method development, validation testing, and system-accuracy testing.
• Working knowledge of mathematical fundamentals, including statistics, trigonometry, and matrices.
• Ability to communicate technical information through written documentation and presentations.

Required Competencies

• Mechanical and systems design for automated equipment.
• Machine vision fundamentals, camera placement, camera aiming, and calibration procedures.
• Industrial robot operation and programming.
• Design for manufacturing, engineering drawings, component selection, and sourcing.
• CAD mesh preparation and modification for simulation.
• Fluid-system and fluid-dispensing fundamentals.
• Electrical-system fundamentals, sensors, and photo eyes.
• Test design, data analysis, root-cause troubleshooting, and technical problem-solving.
• Ability to work independently while collaborating with multidisciplinary engineering teams, suppliers, and customers.
• Ability to organize and manage multiple development activities and priorities.

Software, Equipment, and Tools

• SolidWorks, MATLAB, MeshLab, CAD Exchange, and Meshmixer.
• 3D printers and associated model-preparation or slicing software.
• Industrial robots and robot-programming systems.
• Machine vision cameras and calibration equipment.
• Basic machining, fabrication, mechanical assembly, and electrical test equipment.

Additional Requirements

• Comfortable working in engineering laboratories and manufacturing plant environments.
• Willingness to travel to supplier and customer facilities as required for development, testing, installation, commissioning, troubleshooting, and technical support.

What We Offer

Encore Automation believes high-quality people deliver high-quality systems. We strive to be a Workplace of Choice by offering a comprehensive benefits package available immediately upon hire:

Profit Sharing Plan

401(k) with company match

Flexible work hours

Medical Insurance

Dental Insurance

Vision Insurance

Life Insurance

Short-Term Disability Insurance

Long-Term Disability Insurance

Cell phone reimbursement

Paid holidays

Paid Time Off (PTO)