Senior Mechanical Validation & Test Engineer - Electro-Mechanical Systems

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.
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.
Required Qualifications

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.
Preferred Qualifications

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.
Work Requirements

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.

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