Senior Mechanical Engineer

REP Fitness•Westminster, CO

13d•$125,000 - $155,000•Hybrid

About The Position

REP is hiring a Senior Mechanical Engineer to serve as a senior technical leader on its engineering team. The role owns mechanical design for complex products and product platforms from proof of concept through mass production, working with product line managers, industrial designers, project managers, and department leadership to execute the product roadmap. The engineer will make and defend critical design decisions for projects with significant technical risk and business impact, mentor other engineers, establish design standards, and improve product development practices. The role may include direct reports. The position is based at REP’s headquarters in a hybrid work environment, with at least three days per week in the office and flexibility regarding which days and hours. It involves up to 10% international travel, as well as occasional early or late calls with Asia counterparts and travel to Asia as needed for project support and manufacturing issue resolution. The role includes hands-on work with prototypes and the company’s in-house prototyping shop and R&D lab. The successful candidate will have a bachelor’s degree in Mechanical Engineering or a related engineering field, at least eight years of engineering experience, and a record of excellence in product design and development. They must have taken at least four products from concept to mass production, including at least one as technical lead. The position offers a base salary range of $125,000–$155,000 annually, with bonus potential, and a benefits and perks package that includes health coverage, retirement options with an employer match, paid time off, parental leave, employee gym access, product discounts, and professional development opportunities.

Requirements

Bachelor’s degree from a four-year college or university in Mechanical Engineering or a related engineering field.
At least 8 years of engineering experience.
Demonstrated excellence in product design and development, with at least 4 products taken from concept to mass production, including at least 1 as technical lead.
Proven ability to lead complex projects and engineers to on-time, on-cost launches with minimal oversight.
Ability to set technical direction and make sound decisions with incomplete information, balancing performance, cost, schedule, and risk.
Ability to mentor and develop engineers and give clear, constructive design feedback.
Ability to interpret and apply test and design standards such as ISO and ASTM.
Ability to solve ambiguous, multivariable problems where limited standardization exists.
Ability to turn rough concepts into innovative, patentable designs.
Mastery of engineering fundamentals, including free-body diagrams, stress, strain, deflection, fatigue, dynamic loading, and safety factors.
Expertise in 3D CAD, preferably SolidWorks, and advanced FEA, preferably SolidWorks Simulation, including reviewing and verifying others’ analysis.
Expertise in GD&T and tolerance stack-up analysis.
Experience with PDM and PLM systems and strong project management skills.
Extensive experience with new product introduction from concept to production, including work with overseas contract manufacturers.
Deep knowledge of manufacturing processes including machining, welding, casting, extrusion, forging, punching, and injection molding, and their cost drivers.
Ability to explain complex technical topics clearly to engineers, leadership, and nontechnical partners.
Willingness to work hands-on with physical prototypes.
Willingness to meet early or late for 1–2 calls weekly with Asia counterparts and travel to Asia as needed for project support and manufacturing issue resolution.

Nice To Haves

Experience with fitness equipment standards such as ISO 20957.
Prior experience in the fitness industry or related consumer products.
Experience mentoring or managing engineers or other technical disciplines.
Machine shop capabilities.

Responsibilities

Lead complex, high-impact projects and product platforms through completion with full ownership and minimal oversight, often managing multiple projects or engineers at once.
Architect and design complex mechanisms and assemblies, including injection-molded plastic parts, weldments, castings, and sheet metal, using 3D CAD; develop reusable design architectures across product lines.
Partner with Product Line Managers and department leadership to define customer and engineering requirements, assess feasibility, and influence the product roadmap; collaborate with Industrial Designers to balance aesthetics, function, and manufacturability.
Develop project scope, schedules, cost estimates, and resource estimates; identify risks early and communicate tradeoffs to leadership.
Mentor and develop engineers by delegating work, providing technical guidance, and leading design reviews; the role may manage direct reports.
Serve as a technical authority in design reviews and ensure designs are robust, safe, and manufacturable.
Direct prototype builds and testing in the in-house prototyping shop and R&D lab.
Lead FMEA and risk assessment sessions across product lines and own mitigation plans.
Perform and review advanced FEA simulations, calculations, and tolerance analysis, including fatigue and dynamic loading; verify other engineers’ analysis work.
Define test methodologies and validation plans aligned with industry standards; lead root-cause investigations of complex quality and field issues and drive corrective actions.
Oversee production drawings, bills of materials, and engineering change orders, and approve design changes for assigned product lines.
Lead design-for-manufacturing and cost-reduction efforts with contract manufacturers; resolve escalated manufacturing issues and drive value engineering.
Create and improve engineering standards, design guidelines, and team best practices.
Generate novel concepts, evaluate materials, technologies, and processes, and lead invention disclosures and intellectual property strategies for assigned projects.

Benefits

Medical, dental, and vision coverage.
Health Savings Account with employer contributions.
Flexible Spending Account options.
Long-term disability, short-term disability, life, and AD&D coverage, with premiums fully 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 annual sick leave.
Seven paid company holidays plus an additional floating holiday.
Paid parental leave starting on day one.
Paid birthday off.
Bonus structure rewarding individual and company-wide performance.
Full 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.