Lead Mechanical Engineer

Lead Mechanical Design Engineer — Wearable Audio / AI HardwareA well-funded, early-stage startup is building a next-generation consumer wearable that pushes the boundaries of how humans interact with technology. Backed by experienced operators who have successfully developed and brought wearable products to market, the company is assembling a world-class team to create an AI-powered wearable audio platform from the ground up.We are seeking a Lead Mechanical Design Engineer to drive the development of a high-volume wearable audio product from concept through mass production. This is a hands-on leadership role for someone who thrives in fast-paced environments, operates with high autonomy, and is passionate about building beautifully engineered consumer hardware.LocationBoston areaThis role requires onsite collaboration at least 3 days per week, with additional in-person availability as needed to unblock critical development activities.Travel to Asia is expected approximately 5–10% annually to support manufacturing, supplier engagement, and production ramp activities.What You’ll DoLead the mechanical design and development of a next-generation wearable audio productOwn the product development lifecycle from early architecture and prototyping through EVT, DVT, PVT, and mass productionDrive industrial design integration, packaging, ergonomics, thermal considerations, reliability, and manufacturabilityCollaborate closely with electrical, acoustics, firmware, product, and manufacturing teams to deliver an exceptional user experienceWork directly with overseas manufacturing and supply chain partners to resolve design, tooling, and production challengesDevelop and refine mechanical systems for compact, high-performance wearable devicesConduct tolerance analysis, material selection, DFMEA, and reliability validationBalance aggressive timelines with uncompromising quality standardsHelp establish engineering processes and technical culture within a growing hardware organizationWhat We’re Looking ForSignificant experience developing and shipping high-volume wearable audio products (>50k units)Strong background in earbuds, hearables, wearable consumer electronics, or related compact hardware productsProven experience across the full product development and manufacturing cycleExpertise in mechanical engineering fundamentals, precision design, and mass production processesDeep understanding of materials, tooling, injection molding, adhesives, sealing, and assembly methods for wearable devicesExperience working directly with CM/OEM/JDM partners in AsiaStrong CAD skills (SolidWorks, NX, Creo, or equivalent)Exceptional attention to detail and commitment to product excellenceAbility to work independently and make high-quality engineering decisions with limited oversightComfortable operating in ambiguity and moving quickly in an early-stage startup environmentNice to HaveExperience with acoustic integration and wearable audio system constraintsFamiliarity with reliability testing standards for consumer electronicsKnowledge of antenna integration, thermal management, or miniaturized electromechanical systemsPrior experience at a consumer hardware startup or leading wearable programs at scaleWhy JoinOpportunity to shape a category-defining AI-powered wearable product from the earliest stagesSignificant equitySalary of $175,000+Work alongside an experienced team with a strong track record of bringing breakthrough hardware products to marketHigh ownership, fast execution, and meaningful technical impactCompetitive compensation, equity participation, and the opportunity to help build a generational consumer technology company