Senior Mechanical Engineer (Continuous Improvement)

Responsibilities

• Complete technical ownership of mechanical subsystems and components for current generation WHOOP hardware products, driving improvements from concept through implementation in mass production
• Lead design, analysis, and development of mechanical solutions to improve product performance, reliability, manufacturability, and cost within existing production and design constraints
• Lead engineering change implementation with vendors and contract manufacturers, ensuring clear communication and seamless integration into production
• Define and lead DOE and validation strategies to optimize product and manufacturing performance
• Lead root cause investigations and drive resolution of quality, yield, and reliability issues in production
• Own and maintain CAD models and technical documentation (3D, 2D, BOMs, ECOs) to support design changes, validation, and high-volume manufacturing
• Mentor junior engineers and promote strong engineering best practices
• Travel internationally up to 20% to support manufacturing partners and production builds

Qualifications

• BS or MS in Mechanical Engineering or a related field
• 5+ years of experience in the design, improvement, and sustaining of complex mechanical products, preferably in consumer electronics, wearables, or medical devices
• 4+ years of SolidWorks CAD experience with best practices in part design, tolerance analysis, advanced assemblies, configuration management, and integration of DFx/DfM feedback
• 3+ years of experience working with Tier 1 and 2 contract manufacturers, including driving engineering changes and sustaining production in Asia and North America
• Demonstrated experience with high-volume manufacturing processes (e.g., injection molding, die casting, automated assembly), with a focus on yield, reliability, and cost optimization
• Strong experience in root cause analysis, failure investigation, and implementing design or process improvements in production environments
• Hands-on experience with prototyping and validation to support design changes and production improvements, along with experience in second sourcing, supplier qualification
• Experience leading cross-functional efforts and mentoring junior engineers

Preferred:

• Experience with electromechanical systems, including integration of mechanical components with sensors, PCBs, and flex circuits in compact, high-volume products
• Experience developing and scaling automated test systems, complex fixtures, or production validation infrastructure
• Experience in wearable, health-focused, or other highly constrained consumer electronic products
• Experience leading engineering efforts in fast-paced or startup environments with high ownership and cross-functional influence