Product Design Engineer

Day-O-Lite Manufacturing is building new LED lighting products and needs a hands-on Product Design Engineer to lead engineering execution from early concept through design release. This is an onsite role in Warwick, RI, focused on turning product ideas into production-ready mechanical designs, prototypes, testing, and the documentation needed to get products built.

What you’ll deliver

You will lead the mechanical engineering and detailed design of new LED lighting products, translating concepts into designs that are ready for manufacturing. Your work will run through the New Product Development tollgate process, ensuring engineering deliverables are completed and packaged for design release.

• Own mechanical design work from concept through design release for new LED lighting products.
• Create 3D models, assemblies, production drawings, and engineering documentation using CAD software.
• Develop production-ready drawings including GD&T, tolerances, materials, finishes, and manufacturing requirements.
• Design components and assemblies using relevant processes such as fabricated and formed sheet metal, aluminum extrusions, castings, plastics, spun metal, welding, and more.
• Select and integrate LEDs, drivers, controls, optics, and other electrical and mechanical components.
• Drive design considerations for thermal management, ingress protection, structural requirements, serviceability, and manufacturability.
• Build and evaluate prototypes and support in-house testing, including assembly/QC reviews, thermal testing, water-intrusion testing, and light measurements.
• Produce bills of material and the manufacturing documentation required for design release.
• Support UL/CSA, LM-79, and other applicable testing and certification activities, 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 others.
• Support product cost targets and value-engineering initiatives 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.

Qualifications

• 5+ years of product design or mechanical engineering experience, preferably with manufactured products.
• Bachelor’s degree in Mechanical Engineering, Product Design, or a related discipline, or equivalent relevant experience.
• Advanced CAD proficiency for complex parts, assemblies, and production drawings (SolidWorks and AutoCAD experience expected).
• 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
  • Aluminum extrusion
  • Welding
  • Casting and spinning
  • Injection-molded and vacuum-formed plastics
  • 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.
• IP-rated enclosure design and environmental testing experience 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.

Tools and technologies

• CAD software
• SolidWorks, AutoCAD, AutoCAD (listed), Revit
• AGi32
• SolidWorks Composer

Benefits

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

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.

In-person work location: Warwick, RI