# Senior Mechanical Engineer (Continuous Improvement)

**Company:** [WHOOP](https://hotfix.jobs/companies/whoop)
**Location:** Boston, MA
**Role:** Hardware Engineering
**Experience:** 5+ years
**Skills:** Solidworks, CAD, Injection Molding, Die Casting, Root Cause Analysis, Tolerance Analysis, DFM, High-Volume Manufacturing, Prototyping, Electromechanical Systems
**Posted:** 2026-04-16

> Leads mechanical design improvements, validation, and sustaining engineering for wearable hardware products at scale. Requires 5+ years experience, SolidWorks expertise, and cross-functional collaboration with manufacturers.

## Job Description

## 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

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