Job DescriptionThe Mechanical Engineer is responsible for the mechanical and electro-mechanical design, development, and validation of Headset, Professional Audio and Critical Communications products from concept through production. This role delivers robust, cost-effective, and manufacturable solutions that meet performance, reliability, ergonomic, and regulatory requirements, while supporting customer satisfaction and business objectives.
Key Responsibilities:- Perform mechanical and electro-mechanical research, design, and development of Headset, Professional Audio and Critical Communications products to meet specifications, regulatory requirements, and customer expectations.
- Create assembly, customer, production, and detail mechanical drawings.
- Analyze, develop, verify, and implement product improvements and corrective actions to address quality or performance issues.
- Perform mechanical design, prototyping, verification, and documentation for new and existing products.
- Collaborate with Acoustic Engineering, Mechanical Engineering, Supply Chain, Product Management, Project Management, Manufacturing, and other engineering disciplines to define requirements, research solutions, and implement designs that meet customer and engineering specifications on time and within budget.
- Design and develop headset assembly components (headbands, yokes, hinges, ear-cup housings, sliders, boom arms), speaker cabinets, speaker horns, mounting grids, and related accessories, as well as rackmounted, portable, and desktop electronic enclosures
- Develop and maintain product cost models and monitor product costs throughout the product lifecycle.
- Contribute to design risk analysis by applying structured risk management tools such as Failure Mode and Effects Analysis (FMEA) and Focus Area Matrix methodologies.
- Perform interference and tolerance stack-up analysis for electro-mechanical assemblies.
- Conduct structural, thermal, and fluid dynamics simulations to optimize designs for stress, deformation, stability, airflow, and thermal dissipation.
- Define mechanical constraints and board outlines for printed circuit board assemblies, review PCB layouts for electro-mechanical fit and interference.
- Develop and maintain mechanical and top-level bills of material (BOMs) and assembly drawings.
- Support and participate in regulatory certification and manufacturer specific approval efforts, including preparation of the technical documentation required for Federal Aviation Administration (FAA) compliance.
- Initiate Engineering Change Orders (ECs) to update 3D models and technical documentation.
- Advise manufacturing to update existing product to meet current manufacturing techniques.
- Perform other duties as assigned.
QualificationsRequired Qualifications:- Bachelor's Degree in Mechanical Engineering with 7+ years of experience in product design, including detailed design and testing, material selection, bill of materials development, maintenance, and cost control.
- Proven design experience with injection-molded, sheet metal, and wooden enclosures, electro-mechanical devices, cabling, labels, artwork, and packaging design.
- Strong working knowledge of design and drafting principles, techniques, and industry-standard practices; proficient in SolidWorks (experience with Pro/E and AutoCAD a plus)
- Experience with 3D modeling and electrical/mechanical design interference checking (collaborative IDF process).
- Knowledge of regulatory certification processes and compliance standards, including UL safety certifications and FAA approvals for aviation products.
- Proficient in Microsoft Office applications, including Word, Excel, Project, and PowerPoint.
- Skilled in both virtual and physical prototyping, with the ability to analyze and propose solutions for complex design challenges.
- Capable of performing design verification, including structural, thermal, and fluid dynamics testing and simulation for enclosures, hardware, and mechanical components.
- Experienced in design tolerance analysis and practical application of GD&T principles.
- Self-motivated, able to prioritize and manage multiple tasks, with strong written and verbal communication skills.
- In-depth knowledge of low-volume, high-quality manufacturing techniques.
Required Abilities:- Must be able to lift and carry up to 50 lbs as needed.
Travel:- Occasional travel up to 10% of the time, both domestic and international.
Additional InformationThe U.S. base salary range for this full-time position is $95,000-$105,000 annually. Within the range, individual pay is determined based on several factors, including, but not limited to, work experience and job knowledge, complexity of the role, job location, etc.
- Reasonable accommodations may be made, to the extent they do not pose an undue hardship, to enable qualified individuals with covered disabilities to perform essential functions.
- Indefinite U.S. work authorized individuals only. Future sponsorship for work authorization is not available.
- All of your information will be kept confidential according to EEO guidelines.
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