Senior Mechanical Design Engineer - Completion Tools

We're partnering with a leading completions manufacturer to hire a Senior Mechanical Engineer to own new product design and sustaining engineering across a mature and growing completion tools portfolio (e.g., packers, plugs, frac sleeves, liner hangers, cementing/float equipment, and sand control tools). You'll be the technical driver from concept to commercialization - balancing reliability in HP/HT and sour environments with manufacturability and cost.

• Lead end-to-end mechanical design for downhole completion tools: requirements, concept generation, detailed design, prototyping, validation, and launch.

• Run advanced analysis (stress/fatigue/thermal) and verification using FEA and classical hand-calcs; correlate models with test data.

• Define and execute qualification test plans (pressure/burst/collapse, torque & tensile, sealability, flow/erosion, thermal cycling) including HP/HT and sour service testing.

• Apply API/ISO and company standards (e.g., API 11D1, API 19 series, ISO 15156/NACE MR0175) and author engineering documentation, BoMs, and design dossiers.

• Drive DFM/DFA with Manufacturing & Supply Chain; select materials/coatings/elastomers for harsh service.

• Lead design reviews, mentor junior engineers, and provide field deployment/forensics support as needed.

• Partner with Product Line, Reliability, and Quality to deliver on cost, performance, and schedule.
  
  

• BS/MS in Mechanical Engineering (or related).

• 7-12 years of mechanical design experience with completion tools (any major product line from OEMs or service companies-packers/plugs/liner hangers/frac sleeves/etc.).

• Proficiency in SolidWorks or Inventor, ANSYS (or equivalent FEA), and GD&T per ASME Y14.5.

• Demonstrated success qualifying tools for HP/HT and sour environments; strong materials & elastomer knowledge.

• Hands-on test/rig experience and a data-driven approach to failure analysis and reliability improvement.

• Clear, concise communicator who can influence cross-functionally and mentor others.
  
  

• Knowledge of additive/manufacturing automation, hardfacing, and wear/erosion mitigation.

• Exposure to wireline/coiled tubing deployment or sand control screens.

• Familiarity with downhole hydraulics and sealing mechanics.
  
  

• High-impact role shaping a flagship completions portfolio used globally.

• Lean, empowered engineering culture with real ownership from concept to field.

• Competitive base bonus, strong benefits, and growth path to Lead/Manager or Principal Engineer.

• Relocation support to Houston available for the right candidate.
  
  

• Houston, TX (onsite hybrid). Occasional shop/field and test lab time expected; limited travel for trials and customer support.
  
  

• US work authorization needed - No Sponsorship offered
  
  

Apply now. Shortlisted candidates will be contacted for a confidential discussion.