Manufacturing Mechanical Engineer

About the Role

As a Manufacturing Mechanical Engineer at Sesame, you'll own the mechanical process and fixturing that turns our hardware designs into repeatable, high-yield builds. You'll work directly with our contract manufacturers and tooling partners in Asia - defining assembly processes, specifying and reviewing fixtures, running DOEs, and driving failure analysis when builds don't behave.

This is a hands-on role for someone who may spend up to 90% of your day in MCAD. You'll spend your time in CAD defining fixtures and process tooling, on the floor validating them, and in the data understanding why a station is losing yield. You'll partner closely with Product Design, Test Engineering and Quality as we take products from EVT through mass production.

Responsibilities

• Design and develop assembly fixtures, jigs, and manufacturing tooling using 3D CAD and be comfortable designing assembly fixtures and process tooling yourself.
• Serve as the primary point of contact for fabrication partners in Southeast Asia, and other international partners.
• Procure, assemble, validate, maintain, and improve fixtures, jigs, and related equipment.
• Troubleshoot manufacturing tooling issues to improve quality, yield, and throughput.
• Manage external partners developing fixtures, jigs, test systems, and equipment.
• Partner with Factory Operations leadership to achieve quality and operational goals.
• Collaborate with automation vendors to deploy and optimize robotic manufacturing solutions.
• Evaluate and implement new manufacturing technologies, equipment, and processes.
• Support NPI and process development in collaboration with the U.S. engineering team.
• Travel ~20% to suppliers and manufacturing partners to ensure successful execution.

Required Qualifications

• 7+ years in mechanical engineering, manufacturing engineering, tooling, or related fields.
• Have taken a consumer hardware product from prototype builds through to volume manufacturing
• Have worked directly with contract manufacturers and can hold a technical line with their factory engineers.
• Expert CAD skills and experience designing tooling, fixtures, jigs, or automated equipment
• Strong understanding of materials (plastics, metals, adhesives) and manufacturing processes, including machining, injection molding, stamping, fabrication, and assembly.
• Proven problem-solving ability with experience improving processes, quality, and yield.
• Comfortable working with suppliers, fabrication partners, and engineering teams.
• Bachelor’s degree in Mechanical Engineering or equivalent practical experience.

Preferred Qualifications

• Master’s degree in Mechanical Engineering or equivalent experience.
• 10+ years of experience in consumer electronics, precision manufacturing, or a related industry.
• Experience bringing consumer electronic products from development through production.
• Experience shipping wearable products with demanding industrial design, cosmetic, and quality requirements.

Full-time Employee Benefits

• 401 (k) max employer match: 3.5% of compensation
• 100% employer-paid health, vision, and dental benefits for you and your dependents
• Unlimited PTO and sick time
• Flexible spending account with employer matching up to $1,650/year (medical FSA)
• Guardian Employee Assistance Program (EAP)
• Opportunity to share in the company's success with competitive stock options

Benefits do not apply to contingent/contract workers.