Senior Mechanical Engineer

LLume is developing wearable technology that measures breathing, movement, and performance in real time using our patented Light Lace® fiber-optic sensing platform. Our compact sensor pod integrates optics, electronics, sensing, and wireless connectivity into a wearable form factor designed for comfort and minimal distraction.

• Lead the transition from prototype and low-volume builds into repeatable, high-volume production.
• Develop manufacturing strategies for compact enclosures containing optical, electronic, and mechanical components.
• Design and validate waterproofing systems using gaskets, adhesives, welded joints, membranes, conformal coatings, encapsulation, and electronic potting.
• Develop scalable potting and coating processes, including material selection, dispensing, masking, surface preparation, cure control, coverage inspection, and leak testing.
• Evaluate waterproofing materials for adhesion, flexibility, thermal performance, chemical resistance, optical compatibility, reworkability, and long-term reliability.
• Prevent and resolve defects such as voids, bubbles, incomplete coverage, delamination, contamination, and moisture ingress.
• Drive DFM/DFA, tolerance analysis, material selection, tooling, assembly methods, and production documentation.
• Select and qualify manufacturing partners, equipment, processes, fixtures, and suppliers.
• Lead pilot builds and production ramp, resolving yield, quality, throughput, reliability, and field-performance issues.
• Create verification and validation plans covering ingress protection, leak testing, drop, vibration, thermal cycling, humidity, sweat, corrosion, UV exposure, and mechanical durability.
• Own testing and evaluation from engineering prototypes through EVT, DVT, PVT, certification, and sustained production.
• Coordinate with accredited laboratories and manufacturing partners on applicable certifications and compliance testing, including IP ratings, FCC, CE, UL/CSA, RoHS, and REACH.
• Establish critical-to-quality requirements, PFMEAs, control plans, work instructions, inspection methods, and acceptance criteria.
• Improve unit cost, cycle time, yield, and capacity through data-driven process development.
• Work closely with mechanical, electrical, firmware and product teams.

• 7+ years of experience in manufacturing engineering, NPI, process engineering, product validation, or a related hardware role.
• Proficiency in Computer-Aided Design (CAD) tools for 3D modeling, detailed drawings, and assembly design (e.g., Fusion 360, Solid Works, Creo, or similar).
• Demonstrated ownership of scaling an electromechanical or optoelectronic product from prototypes or hundreds of units into the thousands or tens of thousands.
• Hands‑on experience with potting compounds, encapsulants, and conformal coatings used to waterproof electronics and optoelectronic assemblies.
• Working knowledge of silicone, urethane, epoxy, acrylic, and parylene systems and their manufacturing tradeoffs.
• Experience specifying and validating manual or automated dispensing, coating, curing, masking, and inspection processes.
• Strong experience with waterproof or water‑resistant product design, enclosure sealing, ingress testing, and root‑cause analysis of leaks.
• Experience developing certification strategies and working with independent test laboratories, notified bodies, or regulatory consultants.
• Deep knowledge of environmental, mechanical, reliability, and production testing and evaluation.
• Experience manufacturing precision plastic or metal enclosures using injection molding, CNC machining, die casting, or sheet‑metal fabrication.
• Familiarity with optical alignment, adhesives, fiber routing, sealing, fastening, and sensitive‑component handling.
• Strong knowledge of GD&T, tolerance stack‑ups, manufacturing drawings, fixtures, and inspection methods.
• Experience working directly with contract manufacturers, toolmakers, and component suppliers.
• Practical experience with DOE, process capability, measurement‑system analysis, root‑cause analysis, and yield improvement.
• A hands‑on mindset and comfort operating in a fast‑moving startup environment.

• Experience with wearable…