Mechanical Design Engineer

Position: Mechanical Design Engineer
Location: Sunnyvale, CA (Onsite)
Salary: $110K-$135K ($5K one-time vendor fee paid after 90 days of employment)
Exp: 8-15 years
No H1 Transfers
Key Points: Candidates from phone manufacturing companies (Apple, Google, Samsung……); with AR/VR experience; 2+ yrs of product development in consumer electronics products (like-small form factor, smart glasses, smart watches)


Key Responsibilities

• Lead the mechanical design for a particular component, feature, or system while having end-to-end product development understanding.
• Contribute to mechanical solutions as part of a highly cross-functional team, working closely with electrical engineering, industrial design, operations, and firmware teams.
• Create detailed 3D models and 2D drawings for enclosures, internal structures, and components using CAD software (e.g., Creo, UG NX).
• Model, and iteratively refine prototypes and characterization test systems to validate design concepts and performance goals.
• Build and test prototypes to analyze performance, reliability, and durability under various conditions.
• Optimize space constraints, ensuring tight integration of mechanical parts with electrical components
• Work across the full product development cycle, from concept to ship.
• Research and evaluate materials (plastics, metals, composites) and manufacturing processes such as injection molding, CNC machining, or die-casting, to come up with innovative solutions and approaches for next gen products.
• Collaborate and manage work with Asia-based Supply Chain partners to ensure manufacturability, quality, and cost targets are met.
• Troubleshoot assembly, manufacturing, and system level issues throughout the product lifecycle.

Minimum Qualifications

• BS in Mechanical Engineering or related field.
• 8+ years of industry experience in mechanical design.
• Proficiency in 3D CAD software (Creo, SolidWorks, UGNX).
• Deep understanding of GD&T (Geometric Dimensioning and Tolerancing), DFM (Design for Manufacturability), and DFA (Design for Assembly).
• Experience in Design for Manufacturability (DFM), Design for Assembly (DFA), statistical tolerance analysis techniques, functional dimensioning, geometric tolerancing, and 3D/2D CAD proficiency (e.g., SolidWorks, Creo, NX).
• Working knowledge in material properties, such as plastics, metal, adhesive, glass, etc., and selection for consumer products.
• Testing and analysis experience (FEA, Simulation, Design of Experiments, etc.).
• Experience with FEA (Finite Element Analysis) for structural, thermal, or drop testing.
• Hands-on experience and thorough understanding of high-volume manufacturing techniques (stamping, machining, injection molding, casting, etc.).
• Prior experience in consumer electronics or high-volume precision manufacturing.

Preferred Qualifications

• 10+ years of product design and development experience of handheld and/or wearable electronics for high volume manufacturing, including full systems ownership.
• MS or PhD in Mechanical Engineering.
• Experience designing handheld and wearable electronics for high volume manufacturing.
• Experience with NX CAD software.
• Experience with products cosmetic surface treatments and interfacing with industrial design teams.
• Experience designing for human factors and ergon