Mechanical Engineer - Research & Design (Mid Level)

Job Summary:

We are looking for a Mid-Level Mechanical Product Design Engineer with 2–5 years of experience to design, develop, and refine mechanical components and systems for our products. You will own mechanical design from concept through production, working closely with electronics, firmware, and manufacturing teams to deliver robust, manufacturable, and cost-effective products.

Key Responsibilities:

Design & Development:

• Design mechanical parts, assemblies, and enclosures using 3D CAD software (SolidWorks, Fusion 360, Creo, or similar)
• Create detailed engineering drawings, GD&T tolerancing, and BOMs suitable for manufacturing
• Perform tolerance stack-up analysis to ensure fit, function, and assembly reliability
• Conduct structural and thermal analysis using FEA/simulation tools to validate designs under real-world loads and conditions
• Select materials and manufacturing processes appropriate to the product (injection molding, sheet metal fabrication, CNC machining, die casting, 3D printing) based on cost, volume, and performance requirements

Prototyping & Validation:

• Build and test prototypes at multiple design stages (proof-of-concept, EVT, DVT, PVT)
• Plan and execute functional, environmental, and durability testing; analyze failures and iterate on design
• Document test results and maintain a traceable record of design changes and validation outcomes

Cross-Functional Integration:

• Collaborate with electronics and firmware teams on mechanical-electrical integration — enclosure design, PCB mounting, connector placement, thermal management, and cable routing
• Work with industrial design (if applicable) to balance aesthetics with manufacturability and engineering constraints
• Coordinate with vendors, tooling suppliers, and contract manufacturers on DFM/DFA reviews, tooling design, and cost negotiation

Production Support & Documentation:

• Prepare and maintain technical documentation: drawings, specifications, design reports, and assembly instructions
• Manage engineering change orders (ECO) and engineering change notices (ECN) through the product lifecycle
• Support production ramp-up, troubleshoot mechanical issues on the line, and drive root-cause analysis for field returns/failures
• Contribute to cost-reduction initiatives and design-for-cost (DFC) efforts post-launch

Required Skills & Qualifications:

• Bachelor's degree in Mechanical Engineering or related field
• 2–5 years of hands-on experience in mechanical product design, preferably in consumer electronics, industrial equipment, or hardware products
• Strong proficiency in 3D CAD (SolidWorks, Fusion 360, or equivalent) with a portfolio of shipped or prototyped products
• Solid working knowledge of GD&T, tolerance analysis, and DFM/DFA principles
• Practical experience with plastics (injection molding), sheet metal, and/or machined component design
• Hands-on experience with rapid prototyping methods (3D printing, CNC)
• Working knowledge of FEA tools (SolidWorks Simulation, ANSYS, or similar) for structural/thermal analysis
• Understanding of manufacturing tolerances and their cost implications across processes
• Strong analytical and problem-solving skills with meticulous attention to detail
• Effective communicator, comfortable working cross-functionally with electronics, firmware, and supply chain teams
  

Preferred/Bonus Skills:

• Experience designing IP-rated (IP54/65/67) or ruggedized enclosures
• Experience with thermal management design for electronics-heavy products (heat sinks, vents, fan placement)
• Track record of taking at least one product through full mass production
• Familiarity with compliance standards relevant to the product category (UL, CE, FCC, IP ratings)
• Exposure to sustainability/eco-design considerations (recyclability, material reduction)
• Experience with PLM/PDM tools for design version control

What We Offer:

• Opportunity to own end-to-end mechanical design for real, shipping products
• Close collaboration with a multidisciplinary hardware team