About the RoleWe are seeking a Senior NPI Mechanical Engineer to help establish our mechanical New Product Introduction (NPI) practices from the ground up, guiding hardware programs from concept through early production readiness. In this role, you will be the technical authority on manufacturability, working closely with design, quality, and supply chain teams to build the frameworks, processes, and discipline that let us scale from prototype and beta builds toward repeatable, larger-volume production. You will stand up quality processes and defect-reduction practices sized to where we are today, and own supplier relationships from sourcing through qualification and issue resolution. This is a hands-on, cross-functional role at the intersection of design, manufacturing, and quality, for an experienced mechanical engineer who thrives on creating structure out of ambiguity as much as executing within it.
What You'll DoNew Product Introduction (NPI)- Lead mechanical NPI activities across the full product lifecycle, from concept and early prototyping through pilot builds, ramp, and sustained production.
- Partner with design engineering to review designs for manufacturability, assembly, and testability (DFM/DFA/DFT), influencing decisions early enough to avoid costly late-stage changes.
- Help define and stand up a lightweight, right-sized gate process (EVT/DVT/PVT-equivalent) for our stage, then own the mechanical engineering deliverables (build plans, test protocols, readiness criteria) at each gate as it matures.
- Coordinate cross-functionally with electrical engineering, industrial design, quality, supply chain, and program management to keep NPI programs on schedule and within budget.
Manufacturing Scalability- Evaluate and select manufacturing processes, tooling, and fixturing appropriate for our current build volumes, with an eye toward what will and won't scale as we grow from beta to production
- Identify and resolve bottlenecks in prototype and early pilot builds, laying the groundwork for the throughput and yield improvements we'll need as volume increases.
- Develop and validate assembly processes, work instructions, and line layouts in partnership with contract manufacturers and internal operations teams- largely from scratch, not by inheriting existing documentation.
- Lead design-for-scale reviews to anticipate and mitigate risks before they impact volume production.
Quality & Defect Reduction- Lead defect triage and containment efforts during prototype and pilot builds, partnering with quality engineering - or building that partnership where it doesn't yet exist - to close the loop on recurring issues.
- Define and begin tracking foundational quality metrics appropriate to our build volumes (e.g., first-pass yield, defect rate per build, open issues by severity), evolving toward more statistically rigorous measures like DPPM and field return rates as volumes grow.
- Establish and drive quality processes across the NPI lifecycle, including FMEA, root cause analysis, and corrective/preventive action (CAPA) programs.
- Champion a culture of proactive quality, embedding lessons learned from prior programs into new product designs.
Supplier Management- Lead supplier sourcing, qualification, and onboarding for mechanical components, subassemblies, and tooling.
- Conduct supplier audits and capability assessments to ensure suppliers can meet cost, quality, and volume requirements.
- Manage ongoing supplier relationships, including performance reviews, issue resolution, and escalation management.
- Negotiate and align on technical requirements, specifications, and quality agreements with suppliers and contract manufacturers.
What We're Looking For- Bachelor's degree in Mechanical Engineering or a related field.
- 10+ years of mechanical engineering experience, including significant time in NPI roles- ideally including experience both scaling hardware through high-volume manufacturing and standing up NPI processes from scratch in an early-stage or low-volume environment.
- Demonstrated track record of taking products from concept through mass production, ideally in robotics, consumer electronics, or complex electromechanical systems.
- Strong working knowledge of DFM/DFA/DFT principles, GD&T, and manufacturing processes (injection molding, sheet metal, machining, casting, etc.).
- Hands-on experience with quality methodologies such as FMEA, 8D, root cause analysis, and SPC.
- Proven experience managing supplier relationships, including sourcing, qualification, and issue resolution.
- Experience standing up or scaling manufacturing lines at contract manufacturers.
- Excellent cross-functional collaboration and communication skills, with the ability to influence design decisions and align diverse stakeholders.
- Willingness to travel to supplier and manufacturing sites as needed (domestic and/or international).
Preferred Qualifications:- Experience in robotics, automation, or other complex mechatronic products.
- Familiarity with PLM/ERP systems and NPI program management tools.
- Six Sigma or equivalent quality certification.
- Experience with regulatory and safety compliance requirements relevant to robotics hardware (e.g., UL, CE, ISO).
What We Offer- Comprehensive health coverage for US-based employees, including fully paid medical, dental, and vision insurance, with virtual care and employee assistance resources.
- Meaningful time off to rest and recharge: 23 days of PTO (accrued), separate sick leave, and paid company holidays.
- 401(k) retirement plan with 4% employer match.
- Competitive equity: stock options with meaningful upside as we scale.
- Free daily catered lunch, snacks, and drinks in-office.
- Collaboration with top-tier engineers, researchers, and product experts in AI and robotics.
- Freedom to influence the product and own key initiatives.
For this role in Massachusetts, the expected base salary range is $150K-$190K USD per year; your placement in that range depends on how your experience maps to our internal leveling.
