Mechanical Engineer

Merge Labs is a frontier research lab with the mission of bridging biological and artificial intelligence to maximize human ability, agency and experience. We’re pursuing this goal by developing fundamentally new approaches to brain-computer interfaces that interact with the brain at high bandwidth, integrate with advanced AI, and are ultimately safe and accessible for anyone to use.

About the Team

Merge is building the most advanced interface to the brain, capable of interacting with neurons at unprecedented scale and bandwidth. Delivering that capability in form factors that anyone would want to use will require engineering at the frontier of what’s possible. We’re assembling a team of exceptional builders across electrical engineering, mechanical engineering, mixed-signal IC design, materials science, systems engineering, and engineering physics.

We reason from fundamentals, move comfortably across disciplines, and build technology that scales. We prototype, test, and iterate in tight loops at unreasonable speed because the platform we build makes the science possible.

About the Role

We are seeking a Mechanical Engineer to own the physical architecture and packaging of our BCI systems, spanning early-stage R&D prototypes to product-ready hardware, while also building the instrumentation and tooling that makes our science faster and more reproducible. You will bridge electrical performance, mechanical constraints, manufacturing reality, and experimental workflow. In addition to driving compact integrated hardware from a napkin sketch to manufacturable reality, you will work directly with scientists to replace fragile, one-off setups with fixtures, alignment systems, calibration tools, and instrument subsystems that are repeatable, accurate, and easy for others to operate.

The goal is not simply to help run experiments; it is to engineer away recurring setup work so scientists get meaningful time back and experimental quality improves at the same time. You will own the full mechanical lifecycle, manage critical vendor relationships for fabrication and tooling, and set the standard for mechanical engineering excellence at Merge Labs.

In this role, you will:

• Drive the mechanical architecture and packaging of high-density PCBAs, sensors, mixed-signal components, cables/flexes, thermal interfaces, and user-facing structures, selecting materials and processes that balance performance, durability, manufacturability, and biocompatibility where relevant.

• Execute tight iteration loops using 3D printing, CNC, sheet metal, soft goods, quick-turn tooling, and other rapid fabrication methods to validate form, fit, function, and key engineering risks quickly.

• Own thermal modeling and validation of compact integrated electronic systems, ensuring high-performance ICs operate within strict temperature and form-factor constraints and driving cross-disciplinary thermal solutions across the system architecture.

• Design scientist-facing instrumentation and mechanical tooling—fixtures, jigs, mounts, sample holders, alignment/calibration mechanisms, environmental interfaces, and test stands—that turn manual or expert-dependent setups into repeatable workflows.

• Define quantitative performance and acceptance criteria for those setups, including tolerance, accuracy, repeatability, drift, calibration, environmental stability, and measurement uncertainty as appropriate; validate them with data and document procedures so another user can reproduce the result.

• Own the transition from prototype to production through EVT/DVT/PVT or equivalent, applying DFM/DFA and working directly with vendors to develop tooling, establish inspection/acceptance criteria, and resolve yield or reliability issues.

• Work intimately with…