Senior Mechanical Design Engineer

Job Summary:
A Senior Mechanical Design Engineer (otherwise known as a Research & Development Engineer) at Barnhart is a highly skilled and experienced leader who collaborates with a team to design and produce cutting-edge load handling equipment for use in the heavy lift and heavy transport industry. This role involves spearheading design projects to optimize functionality, safety, efficiency, and value in the equipment used to perform specialized heavy lift and transport work. Senior R&D Engineers leverage their expertise to solve complex challenges, develop innovative equipment, and mentor the next generation of talented engineers. This position offers the unique opportunity to oversee projects from initial concept to final completion, providing a comprehensive and rewarding experience.

Job Requirements:

• Experience: 7+ years of qualifying experience designing mechanical and/or structural equipment for a similar industry with a proven track record of success.
• Certifications: Professional Engineer (PE) license preferred, OSHA 10
• Technical Proficiency: Extensive expertise in mechanical design, structural analysis, and finite element analysis (FEA) for developing and evaluating custom lifting and transport equipment. Demonstrated proficiency with cranes, hoists, hydraulic systems, winches, and rigging equipment, including detailed knowledge of load charts, operational constraints, and safety standards. Skilled in advanced lifting methods such as tandem lifts, heavy load skidding, and modular transport systems. Highly proficient in CAD software (e.g., SolidWorks, AutoCAD, Inventor) for precise design and modeling. Comprehensive knowledge of stress analysis, fatigue analysis, and failure modes, ensuring structural integrity under both dynamic and static loads. Experienced in performing hand calculations and utilizing various programs (e.g., ANSYS, Nastran, Abaqus, RISA-3D) for structural and mechanical evaluations. Strong understanding of materials used in heavy equipment, including steel grades, composites, and high-strength alloys. Adept at integrating mechanical, hydraulic, and electrical systems into cohesive, functional equipment designs. Thorough knowledge of industry standards and regulations, including OSHA, AISC, AWS, ASME B30 Series, ANSI, and ASCE-7, ensuring compliance and adherence to best practices. Proven ability to plan and conduct equipment testing, including load tests, structural validation, and prototype evaluations, with expertise in documenting test results and leveraging findings to optimize designs.
• Software Proficiency: Familiarity with engineering software (i.e. RISA-3D, Ansys Mechanical, Mathcad, MS Excel), as well as ERP systems, scheduling software, video conferencing platforms (WebEx, Zoom, Teams, etc.), and Microsoft Office Suite.
• Problem-Solving and Analytical Expertise: Ability to lead design reviews, troubleshoot performance issues, and implement iterative improvements. Strong analytical skills to address complex engineering challenges and devise innovative solutions. A demonstrated ability to think creatively while adhering to technical and operational constraints.
• Communication: Strong verbal and written communication skills with proven ability to work in cross-functional teams, liaise with clients and stakeholders, and mentor junior engineers in technical disciplines; proficient in preparing and presenting project reports, technical documentation, and equipment operating procedures.
• Project Management Skills: Strong leadership skills with experience in managing project budgets, schedules, and risks, while mentoring a team of engineers and technicians to ensure timely and cost-effective project completion.
• Physical Requirements: Willingness to travel to project sites as needed. Ability to work in a variety of environments, including outdoor and construction sites, and conduct on-site inspections, which may involve standing, walking, crawling, and climbing ladders or scaffolding.
• Fit for Duty: Must pass a drug test, fit for duty and background check.

Job Responsibilities:

• The Senior R&D Engineer leads the design and development of specialized load-handling equipment, ensuring alignment with project requirements and industry standards. The Research & Development process spans the entire project lifecycle and includes the following key phases:
  • Idea Phase: At Barnhart, we continually seek opportunities to improve and grow as an industry leader. Ideas often originate from field personnel, project managers, sales teams, operators, and senior leadership. The R&D team evaluates the viability of these ideas to determine whether they should be pursued further.
  • Concept Phase: During this phase, the team gathers key information and establishes preliminary design parameters. Early-stage CAD models, calculations, and cost estimates are developed to assess feasibility.
  • Development Phase: By collaborating with cross-functional teams, operational, safety, and regulatory considerations are seamlessly integrated into the design process. Concepts are developed into fully engineered solutions, supported by comprehensive calculations and engineering analyses that validate design assumptions. Enhanced modeling techniques including finite element analysis (FEA), stress analysis, and load simulations ensure optimal performance and reliability. Finalized CAD models and fabrication drawings undergo thorough reviews to ensure accuracy and production readiness.
  • Production Phase: The Senior R&D Engineer works closely with the Fabrication Services Department throughout the build process, ensuring strict adherence to design specifications, quality standards, and project timelines. They oversee load testing of specialty rigging tools to verify safety and functionality. Additionally, the Senior R&D Engineer identifies and resolves design or fabrication challenges, implementing effective solutions in partnership with the fabrication team.
  • Implementation Phase: In this final phase, all supporting documents—such as detailed specification sheets, operation and maintenance manuals, and automation calculators—are completed. The Senior R&D Engineer may oversee initial field deployment, documenting lessons learned to drive continuous improvement in future designs.
• Leverage expertise in heavy lift and specialty rigging equipment to develop tailored solutions for customer needs.
• Serve as a field technical liaison for critical lifts, including risk management and safety evaluations for projects.
• Diagnose equipment issues and provide effective solutions, including guidance on repairs.
• Serve as technical reviewer of engineering documents including fabrication drawings, calculations, FEA reports, load test plans, electrical and hydraulic schematics, and specification sheets.
• Manage multiple R&D projects simultaneously, tracking progress, schedules, and budgets to ensure on-time and cost-effective delivery.
• Evaluate project risks and develop mitigation strategies to address technical and operational challenges.
• Drive innovation by researching and implementing emerging technologies, materials, and methodologies to improve equipment performance and efficiency.
• Conduct training events to implement new equipment and teach various Engineering topics.
• Prepare and maintain accurate project documentation such as qualification requirements for operating equipment, design parameters, maintenance requirements, test certificates, work instructions and standard operating procedures.
• Guide junior engineers on technical matters, review their work, and support their professional development.
• Identify opportunities to optimize equipment designs to reduce costs, improve safety, and enhance overall fabrication efficiency.
• Offer real-time technical support during critical lift operations, troubleshooting issues as they arise.
• Communicate project updates, technical details, and engineering solutions to clients and stakeholders to ensure alignment and satisfaction.
• Identify and implement best practices for safety, efficiency, and innovation in crane and rigging projects.
• Keep current with industry trends, new technology, and updated regulatory requirements related to crane and rigging operations.

Compensation and Benefits:

• Competitive salary
• Bonus program that pays for performance
• 401K contributions matched up to 10% of pay
• Benefits Package including medical, dental, vision, short & long-term disability
• Paid Time Off
• Barnhart CARES family care and community service opportunities

Education:

• Bachelor's Degree in Mechanical Engineering, Civil Engineering, or a related field from an ABET accredited 4-year university.

PURPOSE – Barnhart is built on a strong foundation of serving others. The fruit of our labor is used to grow the company, care for our employees, and serve those in our communities and around the world.

MINDS OVER MATTER – Barnhart has built a nationwide reputation for solving problems. We specialize in the lifting, heavy-rigging, and heavy transport of major components used in American industry.

NETWORK – Barnhart has built teams that form one of our industry's strongest networks of talent and resources with over 60 branch locations across the U.S. working together to serve our customers. This growing network offers our team members constant opportunity for career growth and professional development.

CULTURE – Barnhart has a strong team culture -- the “One TEAM.” We are looking for smart, hard-working people who strive for excellence in their work and appreciate collaboration. Join a team that values Safety, Servant Leadership, Quality Service, Innovation, Continuous Improvement, Fairness, and Profit with a Purpose.

EOE/AA Minority/Female/Disability/Veteran