Senior Mechanical Engineer

About Orion

Orion is building the next generation of intelligent sleep technology - thermal regulation, advanced sensing, and beautifully engineered hardware designed to improve sleep quality and long-term health. We’re ramping toward mass production and scaling globally. Mechanical Engineering is core to how our system functions, feels, and performs night after night.

We’re looking for a Senior Mechanical Engineer to own and architect critical mechanical systems across the Orion Sleep System. This role operates at a system level, driving architecture, design quality, manufacturability, and execution from early concept through mass production. You’ll work deeply across thermal systems, fluid routing, enclosures, CMF, mechanisms, and high-precision assemblies, while influencing engineering standards, design direction, and execution velocity.

This is a hands‑on technical leadership role embedded with Operations, Quality, EE, FW, Reliability, and our global manufacturing partners.

• Lead design of TEC-based thermal systems, fluid routing, enclosures, and integrated mechanical assemblies across the Orion Sleep System
• Own detailed CAD, tolerancing, GD&T, and stack-up analysis
• Drive CMF alignment, surface quality, and tooling readiness
• Translate system requirements into robust, production-ready mechanical designs
• Work directly with global manufacturing partners across plastics, sheet metal, machining, and final assembly
• Guide tooling development, design changes, and build readiness for EVT / DVT / PVT and MP
• Support on-site factory builds, failure analysis, and process optimization
• Define and execute validation plans for durability, lifecycle reliability, thermal stability, noise, fit, and cosmetic quality
• Partner with Reliability, QA, and Operations to drive root‑cause analysis and corrective actions
• Maintain drawings, specifications, ECOs, and build documentation
• Collaborate closely with EE and FW on system integration, routing constraints, and sensor placement
• Partner with Product, Ops, and Supply Chain to balance cost, schedule, and manufacturability
• Lead design reviews and technical trade-offs with clarity and ownership

• 7-10+ years of mechanical engineering experience in consumer hardware or integrated electromechanical systems
• Proven system‑level ownership across complex mechanical architectures
• Deep expertise in plastics, sheet metal, mechanisms, thermal systems, and high‑volume manufacturing
• Expert‑level CAD proficiency (Solid Works or equivalent) with strong DFM/DFA and GD&T skills
• Track record of taking products from concept -> EVT -> DVT -> PVT -> MP
• Hands‑on engineering mindset - comfortable in labs, factories, and design reviews
• Strong technical communication and ability to influence across teams without direct authority
• Experience with thermoelectric (TEC/Peltier) systems or thermal‑regulation platforms is a plus
• Experience working with Asian contract manufacturers is a plus
• Strong sensitivity to CMF and cosmetic quality standards is a plus

Mechanical Engineering at Orion is a first‑order function. As a Staff Engineer, you’ll help define the technical foundation of a category‑defining sleep platform and influence how the product scales globally. Your work will directly impact product performance, customer experience, and long-term platform strategy.