Sr. Product Design Engineer

Ironsite AI•San Francisco, CA

6d•$175,000 - $225,000•Onsite

About The Position

Ironsite is building the intelligence layer for the physical world by designing wearable hardware, deploying it alongside craft workers, and transforming shift footage into actionable insights. The company focuses on accelerating construction speed, efficiency, and predictability for complex projects by training AI models on egocentric construction footage and labor productivity data. Ironsite operates with a pro-worker philosophy, aiming to empower the workforce. The technology provides better visibility on-site and ensures the reality of construction is available to project leaders. Ironsite's technology is deployed on major construction projects, capturing extensive footage while maintaining a low worker opt-out rate. The company is backed by prominent investors and operators in technology and construction. Ironsite envisions itself as the foundation for the future of construction, acting as the operating system for building the physical world and promoting greater respect and value for the workforce.

Requirements

5+ years of hands-on experience designing and shipping physical products, with at least one full product lifecycle delivered in wearables, cameras, or ruggedized consumer or industrial hardware at real volume.
Deep experience designing camera integration and optical alignment systems, including owning mechanical integration of imaging systems in production and understanding tolerances, mounting strategies, and IQ tradeoffs.
Experience shipping wearable products, understanding the requirements for comfort, durability, and reliability on a person's body.
Deep expertise designing rugged electromechanical devices for harsh outdoor environments, including sealing, gasketing, and thermal management for enclosures containing electronics.
Strong experience designing parts for mass production, particularly sheet metal, injection-molded plastics, and custom castings.
Hands-on experience working directly with contract manufacturers through DFM reviews, first-article inspection, tooling qualification, and production ramp.
Proficiency with parametric CAD (Onshape, SOLIDWORKS, Siemens NX, Creo, or similar) and comfort with tolerance analysis, FEA, and DFM analysis tools.
Strong cross-functional collaboration with electrical and firmware engineers on PCBA integration, connectors, cable routing, and system-level architecture.
A background in Mechanical Engineering, Product Design Engineering, or a related field, or the equivalent experience.

Nice To Haves

Experience shipping wearable products at consumer volumes (Fitbit, Oura, Whoop, GoPro, Bose, Apple, Meta, Snap, or similar).
Experience designing IP-rated devices (IP65 or higher) for outdoor or industrial use.
Experience with drop, vibration, and environmental test design and validation.
Experience with high-volume injection molding, tooling strategy, and mold flow analysis.
Ability to generate clear technical documentation for internal teams, contract manufacturers, and executive stakeholders.
Familiarity with contract manufacturers in Taiwan, mainland China, or Southeast Asia.
Experience designing helmets, headwear, PPE, or other wearable products that mount on or around the head.
Experience with FCC, CE, or other regulatory certification processes for wearable devices.
Experience with battery pack and optical subassembly mechanical integration.
Familiarity with electrical CAD tools (Altium, KiCad, Eagle) for cross-functional collaboration.
Prior experience as an early mechanical or PDE hire at a hardware startup that scaled from early volumes to full production.

Responsibilities

Own the mechanical design and product architecture of Ironsite's wearable hardware.
Design enclosures, mechanisms, mounts, and thermal systems for ruggedized wearables that must survive active jobsites, including exposure to dust, moisture, impact, and temperature extremes.
Manage fit, ergonomics, sealing, thermal performance, drop and vibration resilience, and manufacturability of the hardware.
Work directly with electrical, firmware, and manufacturing engineering across the full product lifecycle, from concept to volume production.
Own enclosure design, camera mounting and optical alignment, mechanism design, sealing and gasketing, thermal management, and DFM partnership with the contract manufacturer.
Design mechanical systems for precise optical alignment of cameras across temperature, vibration, and impact.
Own tolerances, mounting geometry, and manufacturing controls to ensure consistent image quality.
Design sealing and gasketing systems to meet IP67 targets in jobsite conditions.
Design thermal management systems for reliable operation across environmental extremes and continuous recording loads.
Own drop, vibration, and environmental test plans and iterate on designs.
Design for mass production, including sheet metal, injection-molded plastics, custom castings, and electromechanical assemblies.
Own the DFM review process with the contract manufacturer, drive tooling qualification, and support first-article inspection and production ramp.
Partner with manufacturing engineering on tooling strategy, cycle time reduction, and yield improvement.
Collaborate with electrical and firmware engineers on PCBA integration, connectors, cable routing, and system-level design decisions.
Represent mechanical engineering in design reviews and drive design decisions balancing constraints.
Support contract manufacturers with technical guidance, design updates, and issue resolution during production ramp.