Job Title: Senior Electro-Mechanical Engineer
Location: Sunnyvale, California
Work Arrangement: Onsite
Employment Type: Full-Time / Permanent
Experience: 9 18 Years
Job Summary
We are seeking an experienced Senior Electro-Mechanical Engineer to lead mechanical verification, validation, reliability testing, and automated test-system development for complex electro-mechanical products.
The ideal candidate will combine strong mechanical engineering fundamentals with hands-on expertise in test fixture design, instrumentation, data acquisition, motion control, Python automation, statistical analysis, GD&T, FMEA, and reliability engineering.
This position requires an engineer who can independently define test methodologies, design and build sophisticated test systems, analyze large datasets, and provide technical leadership across engineering and validation activities.
Key Responsibilities
- Define mechanical verification and validation methodologies in collaboration with research, architecture, and product design teams.
- Develop and execute detailed validation and reliability test plans with clearly defined acceptance criteria.
- Perform thermal, vibration, mechanical stress, fatigue, life-cycle, environmental, drop, and related testing.
- Design, build, and qualify electro-mechanical test fixtures and automated test rigs.
- Develop motorized and actuated stages, load and displacement fixtures, cycling testers, vibration setups, and drop-test systems.
- Implement sensor and actuator integration, motion control, microcontrollers, PLCs, and analog and digital I/O.
- Develop Python-based test automation, instrument-control, data-acquisition, and analysis solutions.
- Create reusable analysis pipelines and reporting capabilities.
- Perform FMEA, failure analysis, tolerance analysis, gauge R&R, GD&T, DOE, Weibull analysis, and SPC.
- Select and integrate sensors, instrumentation, and data-acquisition hardware.
- Analyze large datasets and communicate results, trends, risks, and recommendations.
- Support system bring-up, troubleshooting, debugging, and root-cause analysis.
- Track validation coverage, defects, findings, and corrective actions.
- Evaluate and specify capital test equipment and participate in vendor evaluation, acceptance testing, and commissioning.
- Manage external test-fixture and equipment vendors and review technical deliverables.
- Provide technical guidance and mentorship to engineers and technicians.
- Establish standardized, scalable, and repeatable test methodologies.
Required Qualifications
- Bachelor's degree in Mechanical Engineering, Electro-Mechanical Engineering, Mechatronics, or a related technical discipline, or equivalent practical experience.
- 8+ years of relevant electro-mechanical engineering experience with significant exposure to mechanical validation, verification, or reliability testing.
- Demonstrated experience developing and executing mechanical validation and reliability test plans.
- Hands-on experience designing and building instrumented test fixtures and automated test rigs.
- Experience with sensor selection, installation, calibration, and measurement uncertainty.
- Strong Python skills for test automation, instrument control, and data analysis.
- Experience with NumPy, pandas, or comparable data-analysis technologies.
- Experience with analog and digital I/O, DAQ hardware, and sensor signal conditioning.
- Knowledge of communication interfaces such as SPI, I2C, UART, USB, and Ethernet.
- Experience with motion-control technologies including motors, servos, actuators, microcontrollers, or PLCs.
- Strong understanding of mechanical drawings and GD&T.
- Experience with metrology and inspection technologies such as CMM, optical measurement, vision systems, or 3D scanning.
- Experience applying statistical methods including DOE, sample-size justification, Weibull analysis, gauge R&R, and SPC.
- Strong analytical, troubleshooting, communication, and technical leadership capabilities.
Preferred Qualifications
- Master's degree in Mechanical Engineering, Mechatronics, or a related discipline.
- Experience with consumer electronics or highly integrated electro-mechanical products.
- Experience with vibration, shock, transport, and environmental testing standards.
- Experience with optical, non-contact, or full-field measurement technologies.
- Experience with force, pressure, load, and displacement instrumentation.
- Experience with FEA and simulation-to-test correlation.
- Experience developing automated test cells and supporting software infrastructure.
- Experience with test frameworks, databases, dashboards, and automated reporting.
- Experience specifying and commissioning capital equipment and laboratory infrastructure.
- Experience mentoring engineers and standardizing engineering test methodologies.