Mechanical Design Engineer - Maryland

Our client develops wearable and hearable systems for demanding real-world environments. They are seeking a hands‑on Mechanical Design Engineer to own products from early architecture through prototype development, verification, tooling, and production release.

This role is ideal for an engineer who thrives in ambiguous environments, moves quickly, and enjoys solving tightly coupled engineering challenges involving fit, comfort, acoustics, ruggedness, miniaturization, manufacturability, and reliability.

Our client develops wearable and hearable systems for demanding real-world environments. They are seeking a hands‑on Mechanical Design Engineer to own products from early architecture through prototype development, verification, tooling, and production release.

This role is ideal for an engineer who thrives in ambiguous environments, moves quickly, and enjoys solving tightly coupled engineering challenges involving fit, comfort, acoustics, ruggedness, miniaturization, manufacturability, and reliability.

• Own mechanical design from concept and architecture through detailed design, verification, manufacturing release, and production support.
• Explore multiple design concepts, define requirements, evaluate tradeoffs, and select the best solutions under evolving system constraints.
• Create detailed 3D CAD models and 2D engineering drawings.
• Design compact enclosures, mechanisms, cable and connector interfaces, mounts, and structural components for wearable products.
• Build and evaluate prototypes using machining, additive manufacturing, and practical bench fabrication techniques.
• Design products to withstand drop, impact, vibration, flex, ingress, sweat, temperature, wear, comfort, and long‑term lifecycle performance.
• Work directly with suppliers, toolmakers, and contract manufacturers on materials, tooling, process capability, cost, yield, quality, and production readiness.
• Collaborate closely with electrical, RF, audio, firmware, industrial design, and leadership teams to deliver complete product solutions.

• Bachelor’s degree in Mechanical Engineering or a related discipline.
• 2–5 years of hands‑on product development experience. Exceptional recent graduates with strong, relevant project experience are also encouraged to apply.
• Strong proficiency in Solid Works, Creo, or a similar CAD platform.
• Experience designing plastic, silicone, aluminum, titanium, and composite components.
• Demonstrated ability to transform ambiguous requirements into tested, manufacturable hardware.
• Strong fundamentals in mechanics, materials, tolerancing, joints, sealing, thermal considerations, and failure analysis.
• Experience with manufacturing processes such as injection molding, FDM, and SLA 3D printing.
• Ability to manage fast‑moving projects while balancing performance, size, weight, cost, schedule, and manufacturability.
• Experience with wearables, hearables, consumer electronics, medical devices, robotics, defense products, or ruggedized systems is highly valued.