Mechanical Test Engineer

Conduct component- and system-level tests on a dynamometer focusing on thermal behaviour, fatigue cycles, NVH response, and overall durability.

Responsibilities

Conduct component- and system-level tests on a dynamometer focusing on thermal behaviour, fatigue cycles, NVH response, and overall durability; Define test boundaries, run simulations, address real-time issues, and perform teardown analysis to inspect components post-test for wear and failure; Set up instrumentation such as thermocouples, accelerometers, and strain gauges; Prepare pre-test documentation, log deviations, and collaborate with design and quality teams to suggest design modifications based on test outcomes; Perform borescope inspections to detect internal damage like pitting and scoring in gears after endurance tests; Capture and annotate visual inspection findings using videos and images for engineering reviews; Contribute to reliability reports and test summaries, helping determine root causes of issues such as misalignment, improper lubrication, or material fatigue; Analyse collected test data (CAN signals, vibration, torque) to understand system behaviour and support design validation; Filter noise, conduct fatigue analyses, and summarize findings in engineering reports; Organize and export large datasets for trend analysis and comparison with historical data; Optimize filter chains and create reusable data analysis templates in collaboration with CAE teams for fatigue correlation studies; Use CATIA to model and simulate a vertical drop test rig for forklift assemblies, including safety feature design and geometry optimization; Generate detailed 3D and 2D drawings, assign material specs and constraints, and coordinate with manufacturing teams to ensure design feasibility; Simulate assembly sequences and perform fit checks to avoid interference during integration; Perform FEA on drop-test machines to evaluate stress points, fatigue life, and vibration response; Conduct modal and harmonic analyses to assess structural noise and resonance behaviour; Create test scenarios with variable loads and constraints and present simulation results to cross-functional teams for design reviews; Use Vector tools to record vehicle data during forklift test runs for troubleshooting and validating ECU signal transmission; Configure signal databases, monitor bus loads, and interpret DTCs to assist with ECU communication diagnostics and software validation; Conduct virtual simulations using ANSYS and CATIA to validate prototype configurations and identify weak points before manufacturing; Perform material sensitivity analyses and document design iterations for final release; Create test rigs and execute drop tests on forklift components per ANSI protocol, capturing deformation and structural integrity data; Collaborate with safety and compliance teams to ensure drop-test procedures meet OSHA and internal standards; Conduct repeated drop cycles to validate product consistency and maintain trial logs; Diagnose gear and shaft failures using Romax for stress pattern analysis and drivetrain fault detection; Compare simulation outputs with test data to identify gear noise, misalignment, and backlash trends; Carry out tilt tests on forklift models per ANSI standards, measuring inclination and centre of gravity shifts due to operator and cargo weight; Calibrate measuring equipment, prepare setup plans, and coordinate with safety officers during testing; Compile results into regulatory compliance documents and engineering feedback reports.

Requirements

Bachelor's degree or equivalent in Computer Science or equivalent in a related field or foreign equivalent; relevant experience