Senior Mechanical Engineer – Lead Mechanical Engineer (Rugged Hardware)

About the role

We are seeking a Lead Mechanical Engineer to drive the design of rugged enclosures for antennas, sensors and embedded electronics used in mining, construction and large‑scale infrastructure. The role is based in Lisbon and focuses on creating hardware that can withstand extreme UV, weather, vibration and shock while delivering high‑precision positioning and real‑time data.

Key responsibilities

• Design and develop rugged plastic and aluminium enclosures using injection moulding, extrusion, die‑casting and machined parts.
• Create IP‑rated sealing solutions (gaskets, O‑rings, adhesives, ultrasonic welding, over‑moulding) to protect electronics.
• Address thermal management inside sealed boxes and ensure products survive harsh environmental conditions.
• Perform tolerance stacking, Design for Manufacture (DFM) and Design for Assembly (DFA) for volume production.
• Utilise CAD and simulation tools (Autodesk Inventor, SolidWorks, Creo or equivalents) to validate designs before tooling.
• Build and test prototypes with 3D printing, CNC machining and laboratory rigs.

Required profile

• Proven experience designing rugged hardware for industrial applications.
• Strong understanding of material properties, sealing technologies and environmental testing.
• Ability to work independently and lead a specialist hardware team.

Required skills

• CAD software: Autodesk Inventor, SolidWorks, Creo (or equivalent).
• Injection moulding, extrusion, die‑casting and machining processes.
• IP‑rating sealing: gaskets, O‑rings, adhesives, ultrasonic welding, over‑moulding.
• Thermal analysis and management within sealed enclosures.
• Tolerance stacking, DFM and DFA methodologies.
• Prototype fabrication: 3D printing, CNC machining, lab rig testing.