Senior Mechanical Engineer

Overview

TP-Link Systems Inc. is seeking a talented and driven Senior Mechanical Engineer to join our team in Irvine, CA. In this role, you will own the mechanical system architecture (internal layout, construction strategy, and assembly approach) and detailed mechanical design of next-generation consumer networking and smart home products-primarily Wi Fi routers / mesh nodes / gateways.

You will take products from early concept through high-volume manufacturing, working closely with Industrial Design (ID), Electrical/Hardware Engineering, NPI/Operations, and external suppliers/contract manufacturers to deliver production-ready designs.

Key Responsibilities

• Own and drive product-level mechanical system architecture, including internal layout, part breakdown strategy, construction strategy, fastening/joining strategy, datum scheme, tolerance strategy, and serviceability.
• Partner with Industrial Design (ID) to translate design intent into manufacturable mechanical solutions while balancing aesthetics, usability, reliability, schedule, and cost.
• Collaborate with Electrical/Hardware Engineering to define mechanical interfaces and constraints, including PCB outline and mounting, connector/I-O access, assembly datums, fastener strategy, and key keep-outs (as applicable).
• Support thermal and EMI-related mechanical integration, including thermal conduction/heat-spreading paths, shielding strategy implications (contact/compression features, gasket interfaces, conductive coatings), and grounding/contact reliability across tolerance and assembly variation.
• Create and release deliverables using PTC Creo (Creo Parametric): 3D CAD, 2D drawings, specifications, and (preliminary and released) BOMs; apply GD&T and tolerance stack-up on critical interfaces.
• Plan and support prototype builds and validation (EVT/DVT/PVT or equivalent): define build objectives and acceptance criteria; evaluate fit/function, cosmetic, key dimensions, and assembly robustness; drive issue closure through subsequent builds.
• Lead supplier/toolmaker engagement including tooling kick-off and T0/T1/Tn iterations; coordinate mold tuning and dimensional/assembly issue closure with suppliers/CMs.
• Drive DFM/DFA decision-making across manufacturing processes (injection molding, CNC machining, sheet metal, die casting, secondary ops/finishes), including cost/schedule trade-offs.
• Own documentation quality and change discipline: release and maintain drawings/BOMs and drive Engineering Change Orders (ECOs) with clear revision control and supplier communication.
• Participate in root-cause analysis and corrective actions for mechanical issues found during builds, in production, or from field returns.
• Mentor junior engineers through design reviews, best practices, and hands-on coaching (scope/expectations vary by leveling).

Qualifications

• B.S. in Mechanical Engineering or related field; M.S. preferred.
• 5+ years of hands-on mechanical product development experience in consumer electronics, networking products, or electro-mechanical products, including ownership from concept through mass production and demonstrated cross-functional technical leadership.
• Strong proficiency with PTC Creo; able to independently produce release-ready part/assembly CAD, drawings, and BOMs.
• Strong fundamentals in plastics/metals, injection molding, tooling iteration, tolerance/GD&T, and high-volume manufacturing considerations.
• Strong communication skills and demonstrated ability to work effectively in a fast-paced, cross-functional environment.
• Willingness to travel up to 10% to support suppliers/CMs as needed.

Preferred Qualifications

• Experience with compact, high-volume consumer electronics (routers/mesh nodes/gateways or similar products).
• Experience working directly with CMs/toolmakers and closing issues through tooling iterations (T0/T1/Tn).
• Experience working with suppliers, ODM/JDM partners, or contract manufacturers in Taiwan, China, Vietnam, or other Asia-based manufacturing ecosystems.
• Familiarity with rapid prototyping (3D printing, CNC prototypes, soft tooling) and hands-on build/debug support.
• Familiarity with structural simulation/FEA and vibration/shock fundamentals.
• Exposure to PLM/PDM tools and controlled release workflows.

Interview Materials (Remote-Friendly)

Please provide a portfolio (PDF) or be ready to present work samples via screen-share. Confidential details may be redacted.

Salary Range

$145,000 - 155,000

Benefits

• Fully paid medical, dental, and vision insurance (partial coverage for dependents)
• Contributions to 401k funds
• Over four weeks of PTO per year
• Bi-annual pay increases
• Health and wellness benefits, including free gym membership
• Quarterly team-building events

• At TP-Link Systems Inc., we are continually searching for ambitious individuals who are passionate about their work.
• We believe that diversity fuels innovation, collaboration, and drives our entrepreneurial spirit.
• As a global company, we highly value diverse perspectives and are committed to cultivating an environment where all voices are heard, respected, and valued.

• Beyond compliance, we strive to create a supportive and growth-oriented workplace for everyone. If you share our passion and connection to this mission, we welcome you to apply and join us in building a vibrant and inclusive team at TP-Link Systems Inc.
• Please, no third-party agency inquiries, and we are unable to offer visa sponsorships at this time.