Mechanical/Application Engineer - Harnessing

Mechanical/Application Engineer - Harnessing

CO - Longmont | Integrated Cable Systems

Job Title: Mechanical/Application Engineer

Department: Engineering Supervisor: Engineering Manager

Pay Range: $26.00 - $45.00

About Us

ICS is a manufacturer of custom cables, harnesses, electro-mechanical assemblies, and industrial panels. We are a turn-key supplier that enables sophisticated designs.

Job Summary

We are seeking a Mechanical Engineer to join our team at Integrated Cable Systems (ICS), specializing in the design, development, and manufacturing of cable assemblies and wire harnesses for aerospace, defense, and space applications. The ideal candidate will have a strong technical background in electrical and mechanical harness design, be proficient in industry standards, and work closely with cross-functional teams to ensure high-quality and reliable product delivery.

Key Responsibilities

• Design and develop wire harnesses and cable assemblies for aerospace and defense applications.
• Create detailed schematics, wiring diagrams, and assembly drawings using tools such as AutoCAD Electrical or SolidWorks Electrical.
• Perform wire routing and define harness configurations for optimal performance and manufacturability.
• Work closely with customers, engineers, and manufacturing teams to ensure design intent is met.
• Ensure designs comply with IPC/WHMA-A-620, AS9100, MIL-STD, and aerospace industry regulations.

Technical Analysis & Problem-Solving

• Evaluate electrical, mechanical, and environmental constraints to develop robust harness solutions.
• Conduct voltage drop, signal integrity, EMI/EMC, and thermal analysis to validate designs.
• Troubleshoot and resolve design-related issues in prototyping, testing, and production phases.

Manufacturing Support

• Confer with production personnel to resolve production problems as well as explain assembly instructions/techniques to co-workers, optimize manufacturability, and assembly processes.
• Provide design-for-manufacturing (DFM) input to reduce costs and improve efficiency.
• Support first article inspections (FAI) and validation testing to ensure design compliance.

Documentation & Compliance

• Generate and maintain BOMs (Bill of Materials), work instructions, and technical documentation.
• Ensure all harness designs meet customer requirements, AS9100, and industry standards.
• Assist in the qualification and testing of new materials and components.

Cross-Functional Collaboration

• Work closely with procurement and suppliers to source high-quality connectors, wires, and components.
• Support sales and business development teams with technical proposals and customer discussions.
• Participate in design reviews and risk assessments to enhance product reliability.

Required Qualifications

• Bachelor's degree in manufacturing, Mechanical, Electrical Engineering, or related field.
• 3+ years of experience in wire harness and cable assembly design for aerospace, defense, or space applications.
• Proficiency in AutoCAD Electrical or SolidWorks Electrical for schematic and harness design.
• Strong understanding of electrical wiring, interconnect systems, and aerospace harnessing standards.
• Familiarity with IPC/WHMA-A-620, AS9100, MIL-STD, and NASA standards.
• Experience with harness testing, validation, and troubleshooting.
• Ability to interpret engineering drawings, schematics, and wiring diagrams.
• Strong problem-solving skills and ability to work in a fast-paced manufacturing environment.

Preferred Qualifications

• Experience with MES / ERP/MRP systems (Epicor preferred).
• Knowledge of RF cables, fiber optics, and high-speed data transmission.
• Hands-on experience in harness assembly, crimping, and soldering is a plus.
• Six Sigma or Lean Manufacturing experience.