Mechanical Engineer

Job Title: Mechanical Engineer Job Description We are seeking a skilled Mechanical Engineer to research, design, and develop mechanical and electro-mechanical components that meet demanding product specifications, regulatory requirements, and customer expectations. In this role, you create detailed mechanical drawings and documentation, support both new product development and updates to existing products, and collaborate closely with cross-functional teams to deliver high-quality, cost-effective solutions on time and within budget. You play a key role in improving product performance and quality, driving design verification activities, and supporting regulatory approvals for complex mechanical and electro-mechanical systems. Responsibilities + Conduct research, design, and development for mechanical and electro-mechanical components to meet product specifications, regulatory requirements, and customer expectations. + Create detailed mechanical drawings and documentation, including assembly drawings, production drawings, customer-facing documentation, and component-level details. + Identify opportunities for product improvements and implement corrective actions to resolve performance or quality issues. + Support new product development and existing product updates through design, prototyping, testing, and thorough documentation. + Collaborate with Acoustic Engineering, Supply Chain, Product Management, Project Management, Manufacturing, and other engineering groups to define requirements and execute designs on time and within budget. + Design headset components such as headbands, yokes, hinges, ear cups, sliders, and boom arms, as well as speaker enclosures, horns, mounting systems, and related accessories. + Develop rack-mounted, portable, and desktop enclosures for various applications. + Develop and track product cost models throughout the product lifecycle to support cost management and optimization. + Participate in design risk assessments using structured tools such as FMEA and Focus Area Matrix methodologies. + Perform tolerance stack-ups and interference analysis for electro-mechanical assemblies to ensure proper fit and function. + Conduct structural, thermal, and fluid dynamics simulations to improve performance related to stress, airflow, temperature, and overall stability. + Define mechanical constraints for PCB assemblies and review layouts to ensure proper electro-mechanical integration and fit. + Create and maintain bills of material (BOMs) and assembly documentation to support manufacturing and configuration control. + Support regulatory and certification efforts by preparing technical documentation for FAA and other approvals. + Initiate Engineering Change Orders (ECOs/ECs) to update designs and documentation in line with product and process changes. + Provide guidance to manufacturing teams on design updates aligned with current production methods and best practices. + Perform both virtual and physical prototyping to validate designs and solve complex mechanical and electro-mechanical design challenges. + Carry out additional engineering tasks and responsibilities as needed to support project and business objectives. Essential Skills + Bachelor's degree in Mechanical Engineering. + 3-7 years of experience in product design, including detailed design, testing, material selection, BOM development, and cost management. + At least 3 years of injection molding experience within the last 5 years of working experience. + Hands-on experience designing injection-molded parts, sheet metal components, and wooden enclosures. + Experience designing electro-mechanical devices, cabling, labeling, and packaging. + Strong understanding of design and drafting standards. + Proficiency in SolidWorks for 3D modeling and detailed design. + Experience with 3D modeling and interference analysis between mechanical and electrical systems, including IDF collaboration processes. + Experience with design verification, including structural, thermal, and fluid simulations for mechanical systems and enclosures. + Strong knowledge of tolerance analysis and practical application of GD&T principles. + Familiarity with regulatory and compliance requirements, including UL certifications and FAA approval processes. + Proficiency with Microsoft Office tools such as Word, Excel, Project, and PowerPoint. + Ability to perform both virtual and physical prototyping and resolve complex design challenges. + Self-driven and able to manage multiple priorities effectively. + Strong written and verbal communication skills. + Understanding of low-volume, high-quality manufacturing environments. Additional Skills & Qualifications + Experience with Pro/E and AutoCAD is a plus. + Experience with headset components, speaker enclosures, horns, mounting systems, and related accessories. + Experience developing rack-mounted, portable, and desktop enclosures. + Experience in product cost modeling and lifecycle cost tracking. + Experience participating in design risk assessments using FMEA and Focus Area Matrix methodologies. + Ability to collaborate effectively with cross-functional teams across engineering, supply chain, product management, project management, and manufacturing. + Strong problem-solving skills with a focus on improving product performance, quality, and reliability. Work Environment You work in a collaborative engineering environment focused on low-volume, high-quality manufacturing, where precision, reliability, and regulatory compliance are critical. You regularly use SolidWorks and other CAD tools for 3D modeling and interference analysis, along with simulation tools for structural, thermal, and fluid dynamics studies. Daily work involves close interaction with cross-functional teams, including engineering, supply chain, product management, project management, and manufacturing, supported by standard productivity tools such as Microsoft Word, Excel, Project, and PowerPoint. The environment emphasizes rigorous documentation, BOM and ECO management, and support for regulatory certifications such as UL and FAA approvals, while maintaining a professional office and lab setting suitable for both virtual and physical prototyping activities. Job Type & Location This is a Permanent position based out of Burnsville, MN. Pay and Benefits The pay range for this position is $110000.00 - $125000.00/yr. Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors. medical, dental, vision, disability, and life insurance-as well as a 401(k) plan Workplace Type This is a hybrid position in Burnsville,MN. Application Deadline This position is anticipated to close on Aug 28, 2026. About Actalent Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service. The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law. If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email View email address on click.appcast.io for other accommodation options. San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records. Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability. Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.