Mechanical Engineer III

REP Fitness • Westminster, CO

2d • Hybrid

About The Position

As a Mechanical Engineer III at REP, you will lead the mechanical design of new products from proof of concept through mass production. You will collaborate with product line managers, industrial designers, project managers, mechanical designers, contract manufacturers, and department leadership to deliver innovative products that meet customer needs and balance aesthetics, function, manufacturability, and cost. Projects are complex, and the role offers broad latitude to make decisions on critical design elements with minimal oversight.

The position is based at REP’s headquarters in a hybrid work environment, with a minimum of three days per week in the office and flexibility in which days and hours. The role includes up to 10% international travel, occasional travel to Asia for project support, and early or late calls with Asia-based counterparts one to two times weekly. REP’s headquarters has a shared workspace, an in-house prototyping shop and R&D lab, and employee gym access. The role may include mentoring junior engineers and interns.

Requirements

• Bachelor’s degree in Mechanical Engineering or a related engineering field.
• At least 5 years of engineering experience.
• Demonstrated excellence in product design and development, including taking at least 2 products from concept to mass production.
• Ability to independently set and achieve engineering-specific milestones.
• Ability to lead projects that may have multiple people assigned.
• Ability to interpret and apply design and test standards, such as ISO and ASTM.
• Ability to solve practical problems in situations with limited standardization.
• Ability to use novel concepts and rough guidelines to create innovative designs.
• Ability to apply engineering first principles, including free-body diagrams, stress, strain, deflection, and safety factors.
• Expertise in 3D CAD and proficiency in FEA.
• Familiarity with PDM and PLM systems and fluency in project management.
• Experience with new product introduction processes from concept to production.
• Familiarity with manufacturing processes such as machining, welding, casting, extrusion, forging, punching, and injection molding.
• Willingness to work hands-on with physical prototypes.
• Willingness to meet early or late with Asia counterparts one to two times weekly and travel to Asia occasionally as needed.
• Ability to perform the essential duties, with or without reasonable accommodation, and work productively as a team member.

Nice To Haves

• SolidWorks experience; SolidWorks Simulation is preferred.
• Machine shop capabilities.
• Prior fitness industry or related consumer product experience.
• Experience mentoring or managing engineers or other technical disciplines.

Responsibilities

• Lead assigned projects through completion, taking ownership of the mechanical design of one or more products with minimal oversight.
• Design complex assemblies—including injection-molded plastic parts, weldments, castings, and sheet metal bracketry—using 3D CAD.
• Collaborate with Product Managers to define customer and engineering requirements and with Industrial Designers to balance aesthetics, function, and manufacturability.
• Schedule and lead effective meetings with cross-functional teams.
• Occasionally mentor junior engineers and interns, delegate work, and review their designs.
• Build, review, and test prototypes in the in-house prototyping shop and R&D lab.
• Lead FMEA and risk assessment sessions, identify design risks, and define mitigation plans.
• Perform FEA simulations, calculations, and tolerance analyses to identify failure modes, validate factors of safety, meet industry-standard product testing, and ensure reliability.
• Help define test methodologies, interpret test results, conduct root cause analysis, and implement design improvements.
• Work with mechanical designers to create production drawings, bills of materials, and engineering change orders.
• Lead design-for-manufacturing communication with contract manufacturers and review drawings and tooling for manufacturability and cost efficiency.
• Create novel designs and complete invention disclosure forms for intellectual property review.
• Travel internationally, up to 10%, and occasionally travel to Asia for project support.
• Attend early or late calls with Asia counterparts one to two times weekly.

Benefits

• Medical, dental, and vision insurance.
• Health Savings Account with employer contributions.
• Flexible Spending Account options.
• Short- and long-term disability insurance, life insurance, and AD&D coverage, with premiums covered by REP.
• 401(k) and Roth options with employer match up to 4%.
• Employee Assistance Program.
• Four weeks of PTO accrued during the first year.
• 48 hours of sick leave annually.
• Seven paid company holidays and one additional floating holiday.
• Paid parental leave starting on day one.
• Paid birthday off.
• Bonus structure rewarding individual and company-wide performance.
• Access to the employee gym.
• Employee discount on REP equipment, apparel, and nutrition.
• Daily snacks and drinks for onsite employees.
• Company and team-building events.
• Professional growth and development within the organization.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior