Mechanical Project Engineer

About the team:

The Project Engineering team is a multidisciplinary engineering group within Automation Engineering Group, bringing mechanical, electrical, and controls engineering together under a single organization. The team serves as the engineering escalation path for the deployed fleet, taking on problems that exceed field-level troubleshooting and converting them into scoped, engineered, and standardized solutions.

The team's work spans three connected areas. The first is the troubleshooting of complex problems: diagnosing multi-discipline failures across deployed robotic systems and engineering permanent, root-cause fixes rather than repeat repairs. The second is continuous improvement: converting recurring issues and field data into reliability upgrades and fleet-wide standardization. The third is support for existing and new product development and enhancements, in partnership with teams across the organization, to improve equipment currently in the field and to bring new capability online.

Positioned at the intersection of design, commissioning, and field support, the team operates as a cross-functional unit, with engineers at the Bolingbrook hub working alongside field implementation resources across North America. The work is a deliberate blend of reactive support and proactive engineering, and each role on the team contributes to uptime, performance consistency, and long-term customer outcomes across the fleet.

About the role:

As a Mechanical Project Engineer, you will own the mechanical design, documentation, and commissioning of electromechanical systems and assemblies as they are developed, productized, and brought into Formic's automation portfolio. You will lead mechanical design efforts - from concept through SolidWorks modeling, drawing release, and BOM management - while also driving hands-on system integration and floor commissioning to ensure automation systems are proven and production-ready before they scale across Formic's fleet.

This is a hands-on, end-to-end role that blends mechanical design, EOAT development, and floor implementation with proactive product engineering. Working in close collaboration with Project Engineering and Software teams, you will design and release mechanical systems and end of arm tooling (EOAT), maintain organized model and drawing release structures, support the build and commissioning of automation systems on the floor, and develop the training and enablement material that equips Formic's fleet operations and deployment teams. Your work directly impacts mechanical design quality, deployment readiness, and the continued evolution and enhancement of Formic's automation portfolio.

In this role you will:

• Own mechanical design of automation systems and assemblies — including palletizing systems, case packing systems, conveyor systems, material handling systems, and end of arm tooling (EOAT) — from concept through release
• Design, prototype, assemble, and test automated end-of-line automation systems using SolidWorks 3D CAD
• Develop and maintain organized SolidWorks model structures, assembly hierarchies, and controlled model/drawing release processes, including revision control and release documentation
• Create and maintain detailed mechanical design documentation, including CAD models, drawings, exploded diagrams, BOMs, schematics, SOPs, and work instructions
• Design EOAT and implement designs on the floor for build, integration, and commissioning of automation systems
• Implement and integrate electrical, mechanical, and control subsystems, ensuring high performance, reliability, manufacturability, and repeatability
• Rapidly iterate and validate mechanical designs and concepts to ensure exceptional product development delivery timelines
• Lead and manage technical aspects of assigned automation projects within the product roadmap, ensuring milestones, technical specifications, and delivery timelines are met
• Configure, validate, and troubleshoot electromechanical automation systems & assemblies on the floor during build and commissioning
• Support design for manufacturability (DFM) and design for assembly (DFA) practices in collaboration with internal and external resources
• Provide equipment support for Formic's Product & Software teams and technical operations teams
• Collaborate with cross-functional teams to ensure cohesive product delivery and product sustainment
• Troubleshoot & optimize; support debugging of system issues across software and hardware domains and recommend improvements to mechanical design and implementation
• Participate in iterative development cycles by incorporating learnings from field deployments into mechanical design improvements
• Perform root cause analysis, troubleshooting, and resolution of hardware and mechanical system-level issues
• Develop and execute test plans to validate functionality, performance, and compliance with mechanical design requirements
• Engage with external vendors to identify and scope necessary equipment and components
• Interface with external system integrators and OEMs to ensure alignment on mechanical, electrical, and control design specifications
• Continuously collect, aggregate, and assess Deployment and Production Optimization feedback for necessary mechanical design and Continuous Improvement enhancements
• Prepare and deliver weekly internal reporting on progress for key initiatives

What makes you a great fit:

• 3+ years of experience in Mechanical Design, Mechanical Systems Engineering, Mechatronics, Robotics, or a related field
• 3+ years of experience designing mechanical systems, machine assemblies, or equipment for industrial automation and robotic applications
• Experience owning mechanical designs from concept through manufacturing release, including full 3D assemblies, detailed drawings, component selection, and BOMs
• Strong proficiency in 3D CAD, ideally SolidWorks, with experience designing complete machine or system assemblies, not just individual parts
• Strong drafting and GD&T skills, with the ability to produce fabrication- and assembly-ready drawings, exploded diagrams, and BOMs
• Familiarity with industrial robotic systems and their integration, including robotic arms such as FANUC, KUKA, ABB, Yaskawa, Universal Robots, or similar platforms
• Strong understanding of how mechanical systems interface with robotics, EOAT, conveyance, sensors, actuators, guarding, and other automation components
• Experience troubleshooting and diagnosing mechanical problems on automation systems or machinery
• Willingness and ability to work hands-on on the shop floor, including mechanical assembly, integration, testing, troubleshooting, modification, and repair
• Ability to organize and manage engineering deliverables through iterative development and tight feedback loops across concurrent projects
• Excellent problem-solving, critical-thinking, communication, and cross-functional collaboration skills
• Located in, or willing to relocate to, the greater Chicago, IL area and work on-site
• Ability to travel up to 25%

Bonus points if you have: 

• Advanced SolidWorks experience, including large assembly management, top-down design, and configuration-driven design
• Experience designing and implementing robotic end-of-arm tooling (EOAT)
• Experience with end-of-line robotic automation applications such as palletizing, case packing, packaging, conveyance, or material handling
• Experience organizing and maintaining PDM/PLM workflows, revision control, model release structures, and formal drawing-release processes
• Direct hands-on experience with sensors, actuators, motion control systems, motors, and VFDs
• Direct hands-on experience with PLCs
• Familiarity with industrial automation protocols such as EtherNet/IP and IO-Link
• Familiarity with machine safety devices such as safety scanners, light curtains, gate locks, and other guarding/interlock systems
• Knowledge of robotic safety standards such as ISO 10218 and ANSI/RIA
• Experience with AutoCAD or additional 2D/3D CAD platforms