Senior Mechanical Design Engineer
About The Position
LettrLabs is reinventing direct mail with in-house handwriting robotics, challenging traditional direct mail manufacturing. They are seeking a Senior Mechanical Design Engineer to lead the mechanical design and development of complex electromechanical systems from concept to production, contributing to their next-generation production automation platform. This role involves end-to-end project ownership, from translating requirements into manufacturable designs and validating them through analysis and prototyping, to commissioning. The engineer will collaborate with cross-functional teams (electrical, controls, manufacturing, quality) and external vendors. This is a hands-on position requiring comfort with whiteboarding, CAD, and shop floor activities.
Requirements
- 5+ years of experience in mechanical design and product development
- Deep, hands-on experience with motion systems and their core components — belts, pulleys, gears, bearings, and shafts
- Working expertise in sheet metal design and the associated manufacturing methods (bending, CNC machining, laser cutting, waterjet, additive manufacturing)
- Strong command of Design for Manufacturing and Design for Assembly (DFM/DFA)
- Strong fundamentals in mechanical engineering — statics, dynamics, mechanics of materials, tolerancing
- Proven experience with FEA and hand calculations to drive and validate design decisions
- A track record of owning complete mechanical systems and sub-systems from requirements through commissioning
- Experience working directly with vendors and suppliers throughout design and manufacturing
- Bachelor’s degree in Mechanical Engineering or a related field
Nice To Haves
- Master’s degree in Mechanical Engineering or a related discipline
- Experience in robotics, automation, or industrial machinery
- Proficiency with SolidWorks, NX, or similar CAD platforms and PDM/PLM systems
- Familiarity with GD&T (ASME Y14.5) and tolerance stack-up analysis
Responsibilities
- Own entire mechanical systems and sub-systems across the full product lifecycle — requirements generation, concept development, detailed design, analysis, prototyping, validation, and commissioning
- Design precision motion systems incorporating belts, pulleys, gears, bearings, shafts, and related drivetrain components
- Develop sheet metal components and assemblies with a strong understanding of manufacturing processes and tolerances
- Apply DFM/DFA principles to drive cost, quality, and reliability across every design decision
- Perform engineering analysis using hand calculations and FEA to size components, validate designs, and de-risk failure modes
- Select appropriate materials and finishes based on structural, thermal, environmental, and cost requirements
- Build and test prototypes rapidly to validate concepts and iterate quickly toward production-ready designs
- Create and maintain detailed engineering drawings, GD&T, BOMs, and design documentation
- Mentor junior engineers and contribute to design reviews and best practices
Benefits
- Competitive compensation
- Growing benefits
- Equity
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What This Job Offers
Job Type
Full-time
Career Level
Senior
