Mechanical Engineer

Department: Hardware Engineering Location: WahooHQ in Atlanta, GA Reports to: Hardware Engineering Lead The Mechanical Engineer is responsible for designing and developing electromechanical fitness products across Wahoo’s indoor and outdoor training ecosystem, from early concept through mass production and into sustaining engineering and ongoing improvements. This role blends hands-on design, analysis, and lab work with close collaboration across Electrical, Firmware, Industrial Design, and Quality teams to deliver reliable, high-performance products. Responsibilities Own mechanical design of subsystems and assemblies for electromechanical fitness products, including structures, mechanisms, drive systems, enclosures, and interfaces to electronics, from concept through production release. Select and integrate motors, transmissions, and power train components such as belt and gear drives, bearings, shafts, flywheels, and couplings, working closely with Electrical and Firmware teams on control, safety, and performance tradeoffs. Build and iterate robust 3D CAD models and drawings in SolidWorks, including parts, complex assemblies, exploded views, and GD&T, ensuring designs are manufacturable, serviceable, and compatible with Wahoo’s PLM and configuration management practices. Apply engineering analysis including hand calculations, FEA, tolerance stacks, and material selection to ensure structural integrity, stiffness, durability, and reliability under realistic loads and lifetime usage profiles. Define and support verification and validation plans, partnering with lab technicians and Quality to develop fixtures, tests, and pass/fail criteria, analyze test data, support DFMEA, and ensure compliance with regulatory and safety standards. Collaborate with Industrial Design and Product Management to translate user stories and experience requirements into clear mechanical specifications while balancing performance, cost, manufacturability, and aesthetics. Work directly with suppliers and contract manufacturers to bring designs into production, including DFM, DFA, and DFQ reviews, tooling decisions, and issue resolution during EVT, DVT, and PVT builds. Use scripting and simple tools such as Python to streamline engineering workflows, process test data, automate analysis tasks, or support basic test rigs. Collaborate with Firmware and Electrical teams to define interfaces, bring up prototypes, and debug cross-disciplinary issues while maintaining ownership of mechanical design and performance. Minimum Qualifications B.S. in Mechanical Engineering or related field. 3–5 years of experience designing electromechanical products from concept through launch. Strong proficiency in SolidWorks for complex assemblies, detailed drawings, and PLM-controlled releases. Solid understanding of motor-driven system fundamentals including statics, dynamics, fatigue, vibration, friction, bearings, shafts, belt and gear drives, and safety factors. Experience performing structural analysis using hand calculations and FEA in SolidWorks Simulation. Experience with metal manufacturing processes such as machining, sheet metal, extrusions, castings, and stamping, with an understanding of DFM and cost tradeoffs. Experience with plastics and composite manufacturing processes including injection molding and extrusion. Experience planning and interpreting mechanical tests, including durability, abuse, and environmental testing. Comfort working with embedded electronics, sensors, and wiring, including mounting, routing, and strain relief. Strong communication skills and ability to thrive in a fast-moving, cross-functional team. Preferred Qualifications 7+ years of experience designing electromechanical products. Experience with fitness, sports, or cycling hardware such as indoor trainers, smart bikes, or connected exercise equipment. Demonstrated use of modern digital tools, including AI-assisted workflows, to accelerate mechanical design, analysis, or documentation. Experience using Python, MATLAB, or similar tools to automate tests, analyze data, or build engineering utilities. Familiarity with embedded systems and firmware concepts such as control loops, sensor integration, and communication protocols. Experience working within structured product development processes including stage-gate workflows and EVT, DVT, and PVT builds.