Senior Mechanical Engineer

REP Fitness•Westminster, CO

14h•Hybrid

About The Position

REP is hiring a Senior Mechanical Engineer to serve as a senior technical leader on its engineering team. The engineer will own mechanical design for complex products and product platforms from proof of concept through mass production, partnering with product line managers, industrial designers, project managers, and department leadership to deliver the product roadmap. The role carries significant technical risk and business impact and calls for sound, well-defended design decisions. The engineer will also mentor colleagues, 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 environment, with at least three days in the office and flexibility about which days and hours. Responsibilities span product architecture, requirements and planning, analysis, prototyping and validation, manufacturing support, and production release. The role includes up to 10% international travel, travel to Asia as needed, and early or late calls with Asia counterparts one or two times weekly.

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 four products taken from concept to mass production, including at least one as technical lead.
Proven ability to lead complex projects and the engineers working on them to on-time, on-cost launches with minimal oversight.
Ability to set technical direction and make sound decisions with incomplete information while balancing performance, cost, schedule, and risk.
Ability to mentor and develop engineers and provide clear, constructive design feedback.
Ability to interpret and apply test and design standards, such as ISO and ASTM.
Ability to solve ambiguous, multi-variable problems where limited standardization exists and turn rough concepts into innovative, patentable designs.
Mastery of engineering first principles, including free-body diagrams, stress, strain, deflection, fatigue, dynamic loading, and safety factors.
Expertise in 3D CAD and advanced FEA, with the ability to review and verify others’ analysis; SolidWorks and SolidWorks Simulation are preferred tools.
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 non-technical partners.
Willingness to work hands-on with physical prototypes.
Willingness to meet early or late for calls with Asia counterparts one or two times weekly and travel to Asia as needed.

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, potentially 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 through delegation, technical guidance, and 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 REP’s 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’ analyses.
Define test methodologies and validation plans aligned with industry standards; lead root-cause investigations into complex quality and field issues and drive corrective actions.
Oversee release of 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.
Travel internationally up to 10%, including travel to Asia as needed for project support and manufacturing issue resolution.
Work hands-on with physical prototypes and meet early or late for calls with Asia counterparts one or two times weekly.

Benefits

Medical, dental, and vision coverage; competitive benefits packages are available.
Health Savings Account with employer contributions.
Flexible Spending Account options.
Long-term and short-term disability, life, and AD&D insurance, with premiums covered by REP.
401(k) and Roth options with an employer match of 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 plus an additional floating holiday.
Paid parental leave starting on day one.
Paid day off for the employee’s birthday.
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.