Senior Mechanical Engineer (Apparel & Accessories)

country: US all locations: [Boston, MA] commitment: Full Time department: location: Boston, MA team: Hardware RESPONSIBILITIES:: Lead the mechanical design of new WHOOP bands and accessories from initial concept through production ramp, owning form, fit, and function of critical components. Drive product architecture decisions in partnership with Industrial Design, Electrical Engineering, Product Management, and Operations to ensure robust, user-centered solutions. Create and manage high-fidelity CAD models, assemblies, and detailed 2D documentation for both internal design reviews and external manufacturing partners. Spearhead second sourcing and dual tooling efforts for critical mechanical components to ensure supply chain resilience and reduce manufacturing risk. Define and execute validation test plans; apply root-cause analysis to field and manufacturing issues and implement design improvements. Provide technical leadership during design reviews, manufacturing builds, and supplier engagements, both domestic and international. Establish and maintain material specifications, DFM/DFA standards, and mechanical design best practices within the team. Mentor junior engineers, sharing expertise in mechanical design, prototyping, and cross-functional product development. Up to 20% travel to contract manufacturers and suppliers. QUALIFICATIONS:: B.S. in Mechanical Engineering or related field; M.S. a plus. 6+ years of mechanical design experience, with ownership of multiple products through full development cycles. Must demonstrate deep technical fluency in end-to-end product development, including concept creation, prototyping, design iteration, DFM/DFA, EVT/DVT/PVT, and production support. Strong proficiency in 3D CAD (e.g., SolidWorks, Creo) for both concept modeling and detailed production-level design; experience with tolerance stack-ups and drawing standards required. Extensive experience with a range of materials and processes, including plastics, silicones, textiles, elastomers, metals, and overmolding; prior work integrating soft goods and electronics is highly desirable. Proven success working with and managing global suppliers and manufacturers, including qualification and ramp-up support. Demonstrated ability to lead cross-functional initiatives and influence decision-making across teams. Excellent communication and organizational skills; ability to balance technical depth with strategic execution. Passion for product development and attention to detail. Experience working with offshore manufacturing partners preferred. Knowledge of wearables, sports/fitness accessories, or human factors engineering preferred. Familiarity with FEA tools, rapid prototyping, and environmental testing preferred.