Senior Mechanical Engineer (Continuous Improvement)

country: US all locations: [Boston, MA] commitment: Full Time department: location: Boston, MA team: Hardware 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 preferred Preferred 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 Passion for health, human performance, and designing human-centered hardware preferred