Staff Mechanical Engineer

Orion Sleep • San Francisco, CA

1d

About The Position

Orion is developing intelligent sleep technology, including thermal regulation, advanced sensing, and hardware intended to improve sleep quality and long-term health. As Orion ramps toward mass production and global growth, the Staff Mechanical Engineer will own and architect critical mechanical systems across the Orion Sleep System. This system-level role drives architecture, design quality, manufacturability, and execution from early concept through mass production.

The role works across thermal systems, fluid routing, enclosures, color, material, and finish (CMF), mechanisms, and high-precision assemblies. It is a hands-on technical leadership position working closely with Operations, Quality, Electrical Engineering, Firmware, Reliability, and global manufacturing partners. The engineer will influence engineering standards, design direction, and execution velocity.

Requirements

• At least 8 years of mechanical engineering experience in consumer hardware or integrated electromechanical systems.
• Proven system-level ownership across complex mechanical architectures.
• Deep expertise in plastics, sheet metal, mechanisms, thermal systems, and high-volume manufacturing.
• Expert-level CAD proficiency, such as SolidWorks or equivalent, with strong DFM/DFA and GD&T skills.
• Track record of taking products from concept through EVT, DVT, PVT, and mass production.
• Hands-on engineering mindset and comfort working in labs, factories, and design reviews.
• Strong technical communication skills and ability to influence across teams without direct authority.

Nice To Haves

• Experience with thermoelectric (TEC/Peltier) systems or thermal-regulation platforms.
• Experience working with Asian contract manufacturers.
• Strong sensitivity to CMF and cosmetic quality standards.

Responsibilities

• Lead design of thermoelectric (TEC)-based thermal systems, fluid routing, enclosures, and integrated mechanical assemblies across the Orion Sleep System.
• Own detailed CAD, tolerancing, geometric dimensioning and tolerancing (GD&T), and stack-up analysis.
• Drive CMF alignment, surface quality, and tooling readiness.
• Translate system requirements into robust, production-ready mechanical designs.
• Work directly with global manufacturing partners across plastics, sheet metal, machining, and final assembly.
• Guide tooling development, design changes, and build readiness for EVT, DVT, PVT, and mass production.
• Support on-site factory builds, failure analysis, and process optimization.
• Define and execute validation plans for durability, lifecycle reliability, thermal stability, noise, fit, and cosmetic quality.
• Partner with Reliability, QA, and Operations to drive root-cause analysis and corrective actions.
• Maintain drawings, specifications, engineering change orders (ECOs), and build documentation.
• Collaborate with Electrical Engineering and Firmware on system integration, routing constraints, and sensor placement.
• Partner with Product, Operations, and Supply Chain to balance cost, schedule, and manufacturability.
• Lead design reviews and technical trade-offs with clarity and ownership.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior
• Education Level: No Education Listed