Principal Mechanical Engineer - Web Handling

What you'll do:

Shape R2R System Architecture: Serve as the chief architect for next-generation roll-to-roll equipment, dynamic tension systems, precision accumulators, and high-speed winders/unwinders
Research Advanced Winding & Unwinding Technologies: Actively research, evaluate, and benchmark next-generation web handling, winding, and unwinding equipment and technologies to inform tool architecture and roadmap decisions
Lead Cross-Functional Strategy: Translate complex scientific R&D objectives into actionable engineering architectures, bridging mechanical design, process physics, electrical hardware, and closed-loop controls across multiple project groups
Master Web Dynamics & Technical Risk: Drive advanced dynamic modeling, web physics analysis, and experimental validation to resolve critical web defects (e.g., thermal buckling, lateral drift, scratching, or tension transients) in flexible metal substrates
Establish Division Standards: Institutionalize company-wide engineering standards, design guidelines, and testing methodologies for web handling, precision roller design, bearing selection, and mechatronics
Drive Process & Tool Innovation: Pioneer novel mechanical concepts, dynamic guiding schemes, and non-contact web transport modules operating inside temperature zones
Independently Manage Risk: Identify, evaluate, and mitigate high-impact technical risks across major equipment initiatives, establishing contingency paths and robust design margins
Direct Strategic Vendor Partnerships: Audit, qualify, and direct global suppliers and contract manufacturers for specialized R2R sub-assemblies, precision ground rollers, custom surface coatings, and drive components
Organization-Wide Mentorship: Actively coach and mentor Staff, Senior, and Junior mechanical engineers, elevating technical rigor, design review standards, and professional development across the discipline.

What we’re looking for:

• Education: Master’s or PhD in Mechanical Engineering, Mechatronics, or a related field (or equivalent specialized industrial experience)
• Experience:15+ years of proven track record as a recognized technical leader in the architectural design, scaling, and implementation of complex web handling, roll-to-roll (R2R), or converting equipment
• Deep Domain Expertise: Authoritative knowledge of web handling physics—closed-loop tension control, winder dynamics, lateral guiding, roller traction, nip mechanics, load cell integration, and substrate stress distribution
• Cross-Disciplinary Mastery: Demonstrated capability to integrate mechanical systems seamlessly with advanced motion controls, power electronics, and thermal management systems
• Proven Track Record in High-Stakes Tooling: Successful history of bringing first-of-a-kind continuous processing capital equipment from concept through commissioning and high-yield operational scale
• Influential Leadership: Demonstrated ability to drive technical consensus and lead multi-disciplinary teams without relying on formal line management authority

Bonus points for:

• CAD & Simulation Leadership: Advanced mastery of 3D CAD platforms (SolidWorks and/or NX) paired with expertise in multi-body dynamics, non-linear FEA, and finite-difference web simulations
• Brittle & High-Strength Substrate Transport: Specialized experience handling narrow metal tapes, high-strength alloys, or delicate multi-layer composite webs
• Advanced Motion & Control Loops: Deep familiarity with tuning multi-axis servo drives, dancer control algorithms, and adaptive tension loops

Must-have Requirements:

• Ability to occasionally lift up to 50 lbs
• Perform activities such as stooping, climbing, standing, or sitting for extended periods of time
• Dedication to safety to mitigate industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, and cryogenics
• Willingness to travel or work required nights/weekends/on-call occasionally