Senior Mechanical Engineering Consultant – Product Industralisation

Sonexos is seeking an experienced Senior Mechanical Engineering Consultant – Product Industrialisation to provide expert design-for-manufacture (DFM) and industrialisation input as the Company’s Plasma panel platform progresses from mature engineering concepts towards repeatable, scalable manufacture.

The Plasma panel is a compact, multi-material electromechanical assembly combining precision-formed metal components, injection-moulded engineering polymers, specialised films and bonded interfaces, and integrated drive electronics. Its industrialisation draws on a range of established manufacturing processes, executed to tight tolerances and ther technical detail is shared with candidates during the recruitment process.

The Company has developed and matured the principal product concepts, and mechanical design ownership rests with the Company’s internal engineering team. The consultant will provide professional input on DFM and the optimisation of the design for the selected manufacturing processes, review and approve design drawings for production, and act as the Company’s expert liaison with component manufacturers, tooling suppliers, and assembly-equipment providers in relation to mechanical fabrication processes.

An explicit objective of the engagement is capability building: supporting the Company’s internal engineers in honing their DFM and product-engineering skills, so that industrialisation capability is progressively embedded within the internal team.

This is not a conceptual design or research position, and it does not displace the internal team’s design responsibility. The emphasis is on applying credible industrial product-development experience — from products that have actually been manufactured at scale — in an advisory, review, and development capacity. The position reports to the Engineering Director and works in significant collaboration with the Chief Operating Officer, who is responsible for the Company’s supply chain, including components and production.

It is expected to be performed on a part-time consulting basis, with regular presence in or proximity to Lausanne strongly preferred.

• Provide expert DFM input across the Plasma panel and its constituent components — working alongside the internal engineering team, which retains design ownership — through systematic DFM reviews of the design, materials, tolerances, interfaces, assembly methods, and manufacturing assumptions, and recommended design revisions.
• Advise on the optimisation of component and assembly design for the selected manufacturing processes, including metal forming, plastic moulding, wiring and the integration of electronics, sealing and bonding, and the optimal joining and fit of adjoining parts.
• Advise on part-material selection — spanning engineering polymers and metals, and potentially extending to glass and ceramics — and on mechanical specifications, identifying material/process interactions that may affect dimensional control, bonding, assembly, or reliability.
• Review and approve mechanical engineering drawings, tolerance definitions, and specifications for production release, establish clear mechanical acceptance criteria, and ensure design documentation reaches an appropriate level of maturity before production release.
• Act as the Company’s senior technical expert in dealings with component manufacturers, tooling suppliers, and assembly-equipment providers on mechanical fabrication processes — working in close collaboration with the Chief Operating Officer, who is responsible for the Company’s supply chain — reviewing supplier proposals, challenging manufacturing assumptions, and participating in supplier design reviews, tooling trials, process qualification, and manufacturing…