Mechanical Engineer

Job Title: Mechanical Engineer Job Description The Mechanical Engineer will lead the research, design, and development of mechanical and electro-mechanical components and systems that meet product specifications, regulatory requirements, and customer expectations. This role focuses on creating detailed mechanical designs and documentation for headset components, enclosures, and related accessories, while supporting both new product development and updates to existing products. The engineer will collaborate closely with cross-functional teams to deliver robust, cost-effective designs on time and within budget, and will play a key role in product improvement, certification support, and manufacturing guidance. 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, including assembly, production, customer-facing, and component-level documentation. * 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 documentation. * Collaborate with cross-functional teams including 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 to support a variety of product configurations. * Develop and track product cost models throughout the product lifecycle to support cost management and business decisions. * 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 simulations, including structural, thermal, and fluid dynamics, to optimize 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 that align with current production methods and best practices. * Perform additional engineering tasks and responsibilities as needed to support project and organizational goals. Essential Skills * Bachelor's degree in Mechanical Engineering. * 7+ years of experience in product design, including detailed design, testing, material selection, BOM development, and cost management. * 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 and practices. * Proficiency in SolidWorks for 3D modeling and mechanical design. * Experience with 3D modeling and interference analysis between mechanical and electrical systems, including IDF collaboration processes. * Familiarity with regulatory and compliance requirements, including UL certifications and FAA approval processes. * Ability to perform both virtual and physical prototyping and to solve complex design challenges. * 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. * Ability to manage multiple priorities in a self-driven manner. * Strong written and verbal communication skills. Additional Skills & Qualifications * Experience with Pro/E and AutoCAD is a plus. * Proficiency with Microsoft Office tools such as Word, Excel, Project, and PowerPoint. * Understanding of low-volume, high-quality manufacturing environments. * Experience participating in structured design risk assessments such as FMEA and Focus Area Matrix methodologies. * Experience in developing and tracking product cost models throughout the product lifecycle. Work Environment The role operates in an engineering-focused environment that emphasizes low-volume, high-quality manufacturing and close collaboration with multidisciplinary teams, including acoustics, supply chain, product management, project management, manufacturing, and other engineering disciplines. Work involves extensive use of SolidWorks and other 3D CAD tools, as well as Microsoft Office applications for documentation, analysis, and project coordination. The position requires regular engagement in both virtual and physical prototyping, laboratory or workshop-based testing, and participation in regulatory and certification activities. The environment values precision, robust documentation, and adherence to design and drafting standards while supporting innovation and continuous product improvement. Job Type & Location This is a Contract to Hire position based out of Burnsville, MN. Pay and Benefits The pay range for this position is $45.00 - $54.00/hr. Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: • Medical, dental & vision • Critical Illness, Accident, and Hospital • 401(k) Retirement Plan - Pre-tax and Roth post-tax contributions available • Life Insurance (Voluntary Life & AD&D for the employee and dependents) • Short and long-term disability • Health Spending Account (HSA) • Transportation benefits • Employee Assistance Program • Time Off/Leave (PTO, Vacation or Sick Leave) Workplace Type This is a hybrid position in Burnsville,MN. Application Deadline This position is anticipated to close on Aug 3, 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.