Senior Mechanical Validation & Test Engineer - Electro-Mechanical Systems
Full-time
First Soft Solutions
Responsibilities
- Define mechanical verification and validation methodologies in collaboration with research, architecture, and product design teams.
- Conduct thermal, vibration, mechanical stress, and other system-level verification tests.
- Develop, maintain, and track detailed test plans for individual modules and complete systems.
- Design and implement scalable test infrastructure and custom mechanical test fixtures.
- Track test coverage, identify defects, and document resolutions.
- Own system-level mechanical verification and validation execution, analysis, and reporting.
- Drive FMEA, failure analysis, tolerance analysis, Gauge R&R, and GD&T activities in collaboration with process, manufacturing, and reliability engineering teams.
- Support system bring-up, troubleshooting, and debugging.
- Analyze large datasets and communicate test results and findings clearly.
- Manage external vendors for test fixture development, testing, and data collection, ensuring compliance with requirements.
- Design, build, and qualify electro-mechanical test fixtures and rigs, including motorized stages, load and displacement fixtures, automated cycling testers, and vibration and drop-test setups.
- Implement machine I/O and control systems, including sensor and actuator wiring, stepper/servo motion control, microcontrollers, PLCs, and analog/digital interfaces.
- Apply statistical methods, including DOE, sample size and confidence analysis, Weibull reliability analysis, Gauge R&R, and SPC.
- Evaluate and specify capital test equipment, manage vendor evaluations and quotations, and oversee acceptance testing and commissioning.
- Provide technical guidance and mentorship to engineers and technicians while improving test methodologies.
- Bachelor's degree in Mechanical Engineering, Electro-Mechanical Engineering, Mechatronics, or a related technical field, or equivalent practical experience.
- 8+ years of experience in electro-mechanical engineering, with demonstrated expertise in mechanical validation, verification, or reliability testing.
- Experience developing and executing mechanical validation and reliability test plans, including drop, vibration, fatigue/life cycling, environmental, HALT/HASS/ALT testing, and defined acceptance criteria.
- Hands-on experience designing and building test fixtures and instrumented rigs, including sensor selection, mounting, calibration, and measurement uncertainty assessment.
- Proficiency in Python for test automation, instrument control, and data analysis using NumPy, pandas, or equivalent tools.
- Experience with I/O and data acquisition systems, including analog/digital I/O, DAQ hardware, serial interfaces (SPI/I2C/UART/USB/Ethernet), sensor signal conditioning, and motion control.
- Ability to interpret mechanical drawings, apply GD&T, and use metrology and inspection equipment such as CMM, optical/vision measurement systems, and 3D scanning.
- Experience applying statistical methods to test design and interpretation, including DOE, sample size justification, Weibull analysis, and SPC.
- Master's degree in Mechanical Engineering, Mechatronics, or a related field.
- Experience validating consumer electronics, particularly compact or highly integrated products.
- Knowledge of dynamic and environmental testing methods and applicable vibration, shock, transport, and environmental exposure standards.
- Experience with optical, non-contact, or full-field measurement techniques for displacement, deformation, or motion.
- Experience with force, pressure, and load distribution instrumentation.
- Familiarity with FEA and simulation-to-test correlation.
- Experience building automated test cells and supporting software infrastructure, including test frameworks, databases, and dashboards.
- Experience with capital equipment specification, vendor selection, and laboratory setup.
- Experience mentoring engineers and technicians and standardizing test methodologies across teams.
- Ability to develop Python-based automation for test control, data acquisition, and analysis, including reusable analysis pipelines and dashboards.
- This is an onsite position in Sunnyvale, CA.
- Candidates must arrange their own transportation and be able to commute to the work location to meet the required working hours.
Vacancy posted 1 day ago
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