Senior NPI Mechanical Engineer

Flex•Milpitas, CA

1d•$110,100 - $151,400•Onsite

About The Position

Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world. A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment. If you are excited about a role but don't meet every bullet point, we encourage you to apply and join us to create the extraordinary. To support our extraordinary teams who build great products and contribute to our growth, we’re looking to add a Sr NPI Mechanical Engineer located in Milpitas, CA. Reporting to the Director, Program Management, the Sr NPI Mechanical Engineer will will work closely with vendors, suppliers, and external manufacturing partners to ensure mechanical components, assemblies, and full systems meet design intent and quality expectations during all NPI phases. This role is highly engineering-focused, requiring deep mechanical insight, strong build support, rigorous validation, and the ability to solve complex integration issues on the spot.

Requirements

Bachelor’s degree in Mechanical Engineering or related technical discipline.
6+ years of mechanical engineering experience, with significant hands-on hardware development.
Demonstrated experience supporting or leading multiple NPI hardware programs.
Strong understanding of mechanical design, GD&T, tolerance analysis, and fabrication processes.
Proven hands-on engineering skills in assembly, validation, debugging, and failure analysis.
Experience working directly with vendors and contract manufacturers.
Strong communication and technical leadership abilities.
Proficiency with Microsoft PowerPoint, Smartsheet, and Microsoft Project is required to support effective project planning, tracking, and communication.

Responsibilities

Lead hands-on mechanical engineering execution across multiple concurrent hardware NPI programs, ensuring on-time delivery through prototype, EVT, DVT, and PVT builds.
Own mechanical build readiness by driving detailed analyses (tolerance stack-ups, GD&T, DFM/DFA reviews) to ensure manufacturable, assembly-ready designs.
Plan and execute mechanical validation (fit/form/function, reliability testing, failure analysis) and translate results into design/build improvements.
Provide direct build-floor support during prototype and pilot events, performing hands-on assembly, fixture setup, fit checks, torque/alignment, and verification activities.
Rapidly debug and resolve mechanical/electrical/system integration issues, driving containment, root-cause analysis, and corrective actions for build-time failures.
Partner with vendors/CMs/suppliers on mechanical readiness, DFM feedback, tooling/pilot support, and quality acceptance; maintain robust engineering documentation (ECOs, drawings, validation reports, work instructions, FMEAs) and communicate clearly cross-functionally.