Mechanical Design Engineer

About the role

ABB is looking for a Mechanical Design Engineer to join its Mechanical Engineering Team within the SwitchGear Business Line in Egypt. The role focuses on creating and modifying standard designs for sheet‑metal dies and plastic injection molds, producing detailed 3D models and drawings, and supporting tooling production activities.

Key responsibilities

• Design and develop sheet‑metal dies (blanking, piercing, bending, forming, progressive) and plastic injection molds (single/multi‑cavity, family molds).
• Prepare strip layouts, gating systems, cooling layouts and ejection mechanisms.
• Perform engineering calculations such as press tonnage, forming force, bend allowance, shrinkage and tolerance stack‑up.
• Select appropriate tool steels, mold bases, heat‑treatment specifications and standard components.
• Review designs for manufacturability (DFM) and conduct DFMEA and risk analysis.
• Create detailed 3D models, 2D drawings and complete tooling BOMs.
• Support tool‑room activities including CNC machining, wire EDM, grinding, fitting and assembly.
• Participate in tool trials (T0, T1, validation runs) and analyse first‑off samples.
• Troubleshoot and resolve tooling and production issues, implementing corrective design changes.
• Optimize tooling for cycle‑time reduction, scrap reduction, tool‑life improvement and cost efficiency.
• Coordinate with Product Design, Production, Quality and Procurement teams and maintain documentation and revision control.

Required profile

• Bachelor’s degree in Mechanical Design & Production.
• 3‑5 years of experience as a Mechanical Engineer in a medium‑high range company.
• Strong knowledge of production processes, material selection and heat treatment.

Required skills

• Sheet metal die design (blanking, piercing, bending, forming, progressive).
• Plastic injection mold design (single/multi‑cavity, family molds).
• 3D modeling and 2D drafting.
• Tooling bill of materials (BOM) creation.
• Engineering calculations (press tonnage, forming force, bend allowance, shrinkage, tolerance stack‑up).
• Tool steel and mold‑base selection, heat‑treatment specification.
• Design for manufacturability (DFM) analysis.
• DFMEA and risk analysis.
• CNC machining, wire EDM, grinding, fitting, assembly support.
• Tool trial execution and first‑off sample analysis.
• Troubleshooting tooling issues (burrs, cracks, spring back, flash, short shots, sink marks, warpage, dimensional deviations).
• Cost estimation and project tracking.