Senior Mechanical Engineer (Continuous Improvement)

Whoop•Boston, MA

3d•Onsite

About The Position

WHOOP is looking for a Senior Mechanical Engineer to lead and drive critical design improvements, validation strategy, and sustaining engineering efforts for our flagship wearable products at scale. The ideal candidate is a proactive, highly organized engineer with strong problem-solving skills and a sharp eye for detail, thriving in a fast-paced, execution-driven environment and capable of driving creative mechanical solutions with independence and sound technical judgment. This role involves mentoring junior engineers and collaborating cross-functionally with Electrical Engineering, Manufacturing, Supply Chain, Quality, and Program Management to deliver high-impact product improvements driven by customer feedback and evolving business needs. The engineer will work closely with global suppliers and contract manufacturers to execute validation builds and drive and scale design changes in production environments, focusing on high-quality deliverables, robust risk management, clear technical communication, and manufacturing stability. WHOOP operates with urgency, building products for those who push their limits and holding themselves to the same standard. This role is for individuals energized by complex challenges, cross-functional collaboration, and the opportunity to improve hardware products at scale.

Requirements

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

Nice To Haves

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

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