Product Design Engineer

Day-O-Lite Manufacturing is seeking a Product Design Engineer to lead engineering execution for a new LED lighting product development effort, moving from early concept work through design release. This onsite role at Warwick, RI emphasizes turning design intent into production-ready mechanical systems, prototypes, testing, and release documentation.

Role Summary

In this position, you will translate product and design concepts into mechanical designs suitable for manufacturing. You will own key deliverables across the New Product Development tollgate process, including 3D modeling, production drawings, prototype builds, in-house testing, and support for certification and manufacturing documentation.

Key Responsibilities

• Lead mechanical engineering and detailed design of new LED lighting products from concept through design release.
• Create accurate 3D models, assemblies, production drawings, and engineering documentation using CAD software.
• Develop production-ready drawings incorporating GD&T, tolerances, materials, finishes, and manufacturing requirements.
• Execute engineering deliverables throughout the New Product Development tollgate process.
• Design components and assemblies using processes including fabricated and formed sheet metal, aluminum extrusions, castings, plastics, spun metal, welding, and other relevant methods.
• Select and integrate LEDs, drivers, controls, optics, and other electrical and mechanical components.
• Address thermal management, ingress protection, structural requirements, serviceability, and manufacturability through the design cycle.
• Build and evaluate prototypes, conducting in-house testing such as assembly/QC reviews, thermal testing, water-intrusion testing, and light measurements.
• Create bills of material and manufacturing documentation required for design release.
• Support applicable testing and certification activities including UL/CSA, LM-79, and other related work, including DLC.
• Partner with Purchasing and suppliers to evaluate components, sourcing options, tooling, lead times, and product costs.
• Participate in design reviews and cross-functional problem-solving with Manufacturing, Purchasing, Sales, and other teams.
• Support product cost targets and value-engineering efforts while protecting performance, quality, and design intent.
• Provide technical support for existing and custom products as capacity permits.
• Stay current with LED technology, lighting controls, manufacturing technologies, and relevant industry standards.

Requirements

• 5+ years of product design or mechanical engineering experience, preferably with manufactured products.
• Bachelor’s degree in Mechanical Engineering, Product Design, or related discipline (or equivalent relevant experience).
• Advanced proficiency with CAD software for complex parts, assemblies, and production drawings.
• Strong understanding of GD&T, tolerance analysis, and DFMA (design for manufacturing and assembly).
• Hands-on knowledge of manufacturing processes including sheet metal fabrication and forming.
• Hands-on knowledge of manufacturing processes including aluminum extrusion.
• Hands-on knowledge of manufacturing processes including welding.
• Hands-on knowledge of manufacturing processes including casting and spinning.
• Hands-on knowledge of manufacturing processes including injection-molded and vacuum-formed plastics.
• Hands-on knowledge of related tooling and finishing processes.
• Experience designing products that incorporate LEDs, drivers, lighting controls, optics, and thermal-management requirements.
• Understanding of UL 1598 and commercial lighting product safety requirements.
• Familiarity with LM-79/LM-80, photometric testing, and lighting performance evaluation.
• Experience with IP-rated enclosure design and environmental testing is highly desirable.
• Working knowledge of common LED, driver, controls, and lighting-component manufacturers and suppliers.
• Strong hands-on problem-solving skills and the ability to move between CAD design, prototyping, testing, and manufacturing.

Technologies

• CAD software
• SolidWorks
• Auto CAD / AutoCAD
• Revit
• AGi32
• SolidWorks Composer

Preferred Experience

• Previous experience designing commercial or architectural lighting fixtures.
• AutoCAD, Revit, AGi32, or SolidWorks Composer experience.
• Experience working directly with UL or other Nationally Recognized Testing Laboratories.
• Experience supporting products from initial concept through production launch.

Benefits

• 401(k) matching
• Dental insurance
• Health insurance
• Paid time off

Work Location: In person