Mechanical Engineer

Job Title:

Mechanical Engineer

Job Description

The Mechanical Engineer will lead the research, design, and development of mechanical and electro-mechanical components and systems that meet product specifications, regulatory requirements, and customer expectations. This role focuses on creating detailed mechanical designs and documentation for headset components, enclosures, and related accessories, while supporting both new product development and updates to existing products. The engineer will collaborate closely with cross-functional teams to deliver robust, cost-effective designs on time and within budget, and will play a key role in product improvement, certification support, and manufacturing guidance.

Responsibilities

* Conduct research, design, and development for mechanical and electro-mechanical components to meet product specifications, regulatory requirements, and customer expectations.

* Create detailed mechanical drawings, including assembly, production, customer-facing, and component-level documentation.

* Identify opportunities for product improvements and implement corrective actions to resolve performance or quality issues.

* Support new product development and existing product updates through design, prototyping, testing, and documentation.

* Collaborate with cross-functional teams including Acoustic Engineering, Supply Chain, Product Management, Project Management, Manufacturing, and other engineering groups to define requirements and execute designs on time and within budget.

* Design headset components such as headbands, yokes, hinges, ear cups, sliders, and boom arms, as well as speaker enclosures, horns, mounting systems, and related accessories.

* Develop rack-mounted, portable, and desktop enclosures to support a variety of product configurations.

* Develop and track product cost models throughout the product lifecycle to support cost management and business decisions.

* Participate in design risk assessments using structured tools such as FMEA and Focus Area Matrix methodologies.

* Perform tolerance stack-ups and interference analysis for electro-mechanical assemblies to ensure proper fit and function.

* Conduct simulations, including structural, thermal, and fluid dynamics, to optimize performance related to stress, airflow, temperature, and overall stability.

* Define mechanical constraints for PCB assemblies and review layouts to ensure proper electro-mechanical integration and fit.

* Create and maintain bills of material (BOMs) and assembly documentation to support manufacturing and configuration control.

* Support regulatory and certification efforts by preparing technical documentation for FAA and other approvals.

* Initiate Engineering Change Orders (ECOs/ECs) to update designs and documentation in line with product and process changes.

* Provide guidance to manufacturing teams on design updates that align with current production methods and best practices.

* Perform additional engineering tasks and responsibilities as needed to support project and organizational goals.

Essential Skills

* Bachelor's degree in Mechanical Engineering.

* 7+ years of experience in product design, including detailed design, testing, material selection, BOM development, and cost management.

* Hands-on experience designing injection-molded parts, sheet metal components, and wooden enclosures.

* Experience designing electro-mechanical devices, cabling, labeling, and packaging.

* Strong understanding of design and drafting standards and practices.

* Proficiency in Solid Works for 3D modeling and mechanical design.

* Experience with 3D modeling and interference analysis between mechanical and electrical systems, including IDF collaboration processes.

* Familiarity with regulatory and compliance requirements, including UL certifications and FAA approval processes.

* Ability to perform both virtual and physical prototyping and to solve complex design challenges.

* Experience with design verification, including structural, thermal, and fluid simulations for mechanical systems and enclosures.

* Strong knowledge of tolerance analysis and practical application of GD&T principles.

* Ability to manage multiple priorities in a self-driven manner.

* Strong written and verbal communication skills.

Additional

Skills & Qualifications

* Experience with Pro/E and AutoCAD is a plus.

* Proficiency with Microsoft Office tools such as Word, Excel, Project, and PowerPoint.

* Understanding of low-volume, high-quality manufacturing environments.

* Experience participating in structured design risk assessments such as FMEA and Focus Area Matrix methodologies.

* Background in developing and tracking product cost models throughout the product lifecycle.

Work Environment

The role operates in an engineering-focused environment that emphasizes low-volume, high-quality manufacturing and close collaboration with multidisciplinary teams, including acoustics, supply chain, product management, project management, manufacturing, and other engineering disciplines. Work…