Senior Mechanical Design Engineer

Job Summary

Position Overview:
Insulet is the world’s leading manufacturer of high-volume, disposable, electromechanical, wearable medical devices. As a Sr. Mechanichal Design Engineer/ Automation Engineer in the Global Equipment Engineering Group, the candidate will support both current manufacturing operations as well as new product development by providing expertise related to the continuous improvement efforts for existing manufacturing processes/equipment. The candidate will also work with internal customers and external vendors to specify, procure, and install new manufacturing lines and equipment in accordance with business needs. The candidate will work in a collaborative team environment with manufacturing, manufacturing engineering, metrology, quality and component supplier engineering. Responsibilities include working with cross-functional teams and / or strategic partners and providing technical guidance to support project execution. This role is suitable for an energetic problem solver who has solid technical, organizational and communication skills.

Responsibilities:

The successful candidate will primarily focus on the design, development, specification and implementation of automated equipment for assembly and packaging processes. In addition, continuous improvement efforts, obsolescence programs, technology transfers and new product development may also be exercised in support of business objectives. Important job qualifications include:
• Experience in specifying, selecting, manufacturing acceptance, installation, startup, commission, and validation of fully automated and advanced discrete component assembly and / or packaging technologies. A sound mechanical skillset incorporating machine design principles and a strong mechanical aptitude is required.
• Technical mastery in mechanical engineering, namely assembly technologies and packaging (i.e. blister forming, cartoning, bagging, sealing etc.), is preferred. Technical mastery in the following areas is sought:
• Hands-on mechanical aptitude and machine design including pneumatics, linkage design, mechatronics, robotics, and drive systems.
• Process technologies: ultrasonic welding, heat transfer decoration, hot stamping, laser welding, laser decoration.
• Packaging: material knowledge, cartoning, conveyor systems and sealing technologies.
• The demonstrated ability to understand user requirements of complex types of products, translate these into a complete conceptualized automated solution; Creates or coordinates the design solutions for novel or complex problems; integrates regulatory and operational needs, and assesses cost benefit. Having done so in a regulated and/or medical device industry is a plus.
• The management and oversight of vendor communications and collaboration is required. Ability to critically review engineering designs and ensure adherence to company design and development guidelines and SOPs. Proven ability to manage multiple projects is required. Experience with formal project management is a plus. Ability to successfully lead teams and vendors to achieve exceptional results.
• Responsible for managing the IQ, OQ, FAT, SAT and PQ efforts for new assembly and packaging technologies and / or transferring technologies to new factory sites.
• The individual must be able to build the capability of others to ensure successful project execution. Engages and energizes others to reach their fullest potential and performance. This can include, but is not limited to improving business process systems, developing training aids and SOPs, and providing feedback to discipline owners for future designs. In addition, knowledge and experience with post-implementation continuous improvement efforts and methodology is beneficial.
• Candidate should have good problem-solving skills and be capable of responding to barriers, problems, and challenges with internal manufacturing or external equipment suppliers. Candidate needs to be able to effectively deal with conflict and openly communicate and lead team members to successful resolution. Demonstrated ability to work effectively while leading others in a teaming environment across multiple geographical locations and across various functional areas and roles. The candidate must possess strong verbal and written communication skills.
• Possessing a solid understanding and demonstrated ability of implementing machine and process safety considerations is a strong plus. Knowledge of CE, UL, SCCR & NFPA-70E&79 regulations a plus. In addition, demonstrated application of domestic and international standards is a plus (DIN, ASME, ISO).
• Support capacity‑expansion initiatives, including planning, specification, procurement, installation, and validation of new manufacturing lines and equipment to meet long‑term business growth objectives.
• Lead cross-site and cross-functional coordination (manufacturing, quality, maintenance, supply chain, suppliers) to ensure alignment on technical deliverables, timelines, production readiness, and quality standards.
• Serve as a primary liaison for global project execution, bridging Global Automation Engineering with regional manufacturing sites to ensure consistent implementation of automation strategy and equipment standards.
• Oversee commissioning, qualification (IQ/OQ/PQ), FAT, and SAT for new automation technologies and ensure successful transfer of equipment to new or existing factory sites.
• Manage vendor communications, design reviews, and technical alignment, ensuring machines meet internal standards, design guidelines, regulations, and user requirements.
• Lead project planning for automation initiatives, including milestone creation, risk identification/mitigation, resource planning, and issue escalation to leadership.
• Support capital project execution, including CAR development, budgeting, cost tracking, and forecast updates to ensure adherence to financial plans.
• Execute and support technology transfers for manufacturing equipment being relocated or newly deployed at global sites, ensuring seamless startup, training, and stabilization.
• Drive continuous improvement and obsolescence reduction programs, ensuring long‑term equipment reliability, performance, and maintainability across the automation portfolio.
• Provide leadership and mentorship to project team members, onsite engineers, and vendor engineering teams to ensure strong technical execution and cross‑functional collaboration.

Preferred Requirements:

• Bachelor of Science in Mechanical Engineering. Master of Science in Mechanical Engineering is a plus.
• 6+ years of hands-on machine design experience.

Preferred Skills and Competencies:
• Demonstrated flexibility and ability to function in a fast-paced, growth industry and work environment.
• Strong organizational skills.
• Strong interpersonal skills
• Strong communication skills (both verbal and written) and the ability to effectively communicate both internally and externally, as well as to upper management.
• Strong command of structured problem-solving tools.
• Prior evidence of successful participation in work teams where combined contribution, collaboration, and results were expected.
• Demonstrated proficiency in common computer tools such as word processing, spreadsheet, and web-based applications.
• Proficiency with the use of CAD modelling software (SolidWorks preferred).
• Working knowledge of Minitab and/or JMP statistical analysis software.
• Experience with data analysis and data driven decision making
• Ability to lead cross‑functional and cross‑site technical activities, including vendor coordination and global project execution.
• Strong project management capability, including scheduling, risk mitigation, and supporting capital project deliverables.
• Experience with automation line startup and equipment commissioning, including debugging and validation.
•Solid understanding of automation technologies such as robotics, motion systems, PLC‑based equipment, and vision systems.
• Working knowledge of machine and process safety requirements (CE, UL, NFPA).
Physical Requirements:

• The successful candidate must be able to travel domestically and internationally as business needs demand. Travel is estimated at 30%.
• The successful candidate will perform other duties as required.



Insulet started in 2000 with an idea and a mission to enable our customers to enjoy simplicity, freedom and healthier lives through the use of our Omnipod® product platform. In the last two decades we have improved the lives of hundreds of thousands of patients by using innovative technology that is wearable, waterproof, and lifestyle accommodating.