Jobid=910325f5f15f (0.02)
Role purpose
Sofis is looking for a Senior Mechanical Engineer to join our product development and lead the design and development of new mechanical products, with a strong focus on pneumatic and electric portable valve actuators for demanding industrial environments. You will play a key role in expanding and improving our portfolio of portable actuators and related valve operation systems used in the oil, gas, petrochemical and energy industries.
About Sofis
Sofis is a global manufacturer of valve operation systems, including mechanical valve interlocks, portable actuators and valve position indicators used to ensure safe and efficient operation of manual valves. Our products are installed worldwide in refineries, tank terminals, chemical plants and power generation facilities, helping customers operate manual valves safely, efficiently and ergonomically.
Sofis is part of Halma plc, a UK‑based FTSE 100 group of specialist safety, health and environmental technology companies. Halma brings a global network of around 45 companies and 7,000–9,000 employees, giving Sofis the backing and growth potential of a large international group while retaining the focus and agility of a specialist engineering company.
Key responsibilities
- Lead the mechanical design and development of pneumatic and electric portable valve actuators, including gearboxes, motor couplings, valve interfaces and safety-related components.
- Translate functional requirements (torque, speed, duty cycle, ergonomics, ATEX/IP, etc.) into robust mechanical and electromechanical designs suitable for harsh industrial environments.
- Design and develop gear sets (gear trains, gearboxes, reaction arms) and their integration with pneumatic and electric motors, ensuring reliable torque transmission and operator safety.
- Engineer mechanical interfaces and mounting kits between actuators and a wide variety of manual valves and gearboxes (handwheel, lever and gearbox-driven valves).
- Perform engineering calculations and FEM/FEA simulations (strength, fatigue, stiffness, safety factors) to optimize designs for reliability, weight, cost and manufacturability.
- Build, test and refine prototypes using 3D-printed and machined parts, iterating quickly from concept to validated design.
- Define and execute test plans (functional, durability, environmental, IP/ingress, torque/speed) and support certification-related testing where required.
- Prepare complete 3D models, 2D production drawings, tolerance stacks and BOMs in SolidWorks, and support transition into industrialization.
- Collaborate closely with electronics/controls colleagues on electromechanical modules (electric motors, torque control, speed control, safety interlocks).
- Work with suppliers on manufacturability, component selection and production tooling; support sample builds, validation and release to production.
- Provide expert mechanical engineering support to internal stakeholders (Sales, Product Management, Operations, Quality) on product design questions and complex customer applications.
- Contribute to the continuous improvement of existing products and to the development of new concepts and platforms for portable actuators and valve operation systems.
Required qualifications and experience
- Bachelor’s or Master’s degree in Mechanical Engineering or closely related discipline.
- 7–10+ years of experience in mechanical design and development roles, preferably in industrial equipment, power tools, actuators, gearboxes or similar rotating machinery.
- Proven track record in designing gear trains/gearboxes and integrating them with pneumatic or electric motors (couplings, torque transfer, alignment, noise and vibration).
- Strong hands-on background: comfortable building, assembling, troubleshooting and testing mechanical and electromechanical prototypes and test rigs.
- Demonstrated experience taking products from concept through prototyping, testing, design finalization and release into production.
- Advanced 3D CAD skills (SolidWorks or equivalent) for complex assemblies, 3D modeling, 2D drawings, GD&T and creation of production-ready documentation.
- Experience using FEM/FEA tools for structural and fatigue analysis of mechanical components and assemblies.
- Solid understanding of manufacturing processes for mechanical components (machining, casting, forging, sheet metal, heat treatment, surface treatments, etc.) and their impact on design.
Desirable domain knowledge
- Experience with pneumatic tools or motors, including torque/speed characteristics, air supply requirements and control via throttles or valves.
- Experience with electromechanical products such as electric torque tools, power tools or actuators, including electric motors, torque and speed control, and basic electronics integration.
- Familiarity with ATEX requirements and standards for mechanical and electromechanical equipment used in potentially explosive atmospheres (oil, gas, petrochemical environments).
- Familiarity with IP (Ingress Protection) ratings and sealing concepts, and their implications for enclosure design, bearings, gaskets and interfaces in industrial tools.
- Experience in designing products for harsh industrial environments (outdoor use, contamination, temperature extremes, rough handling, ergonomics and operator safety).
- Knowledge of valve technology and valve operation (gate, globe, ball, butterfly valves, gearboxes and valve interlocks) is a strong plus.
Tools and methods
- Expert user of SolidWorks (or similar) for 3D modeling, 2D drawings, assemblies, exploded views and detailed manufacturing documentation.
- Experience with FEM/FEA software (e.g., SolidWorks Simulation, ANSYS, or comparable) for structural and fatigue analysis.
- Ability to prepare and use 3D-printed parts and simple fixtures to quickly prototype design concepts and validate fit, ergonomics and assembly sequences.
- Comfortable working with standard engineering toolsets: tolerance analysis, failure mode and effect analysis (FMEA), design reviews, risk assessments, DfM/DfA methods.
Soft skills and personal attributes
- Strong problem-solving mindset, able to break down complex technical challenges and generate innovative and practical design solutions.
- Passionate about research, analysis, simulation, design, testing, prototyping and continuous optimization of products and processes.
- Strong communication skills in English, both spoken and written; able to clearly explain design intent and trade-offs to technical and non-technical stakeholders.
- Team player with a collaborative attitude and the ability to work effectively in multidisciplinary and international teams.
- High level of ownership and accountability; able to drive tasks independently while keeping stakeholders aligned.
- Curious, eager to learn and willing to quickly build expertise in new technologies, standards and application domains.
Reporting
This role is part of the Sofis R&D/New Product Development team and reports to the Head of Product Development. The position is full-time (40 hours per week) with some flexibility for hybrid working in line with company policy.
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