Sr. Mechanical Engineer

Senior Mechanical Engineer, Advanced EngineeringBased in North Kingstown, RI, the Senior Mechanical Engineer, Advanced Engineering turns ambiguous, high-potential ideas and technologies into real, testable electro-mechanical prototypes, systems, Proof of Concepts, and Proof of Technologies. This role bridges early-stage innovation and standard NPD by rapidly advancing concepts from approximately TRL2 to TRL6, de-risking the critical unknowns needed for credible Phase 0 business case inclusion and decisions.Role archetype: Creative Innovation Engineer / "MacGyver-minded" mechanical engineer. A practical inventor who combines CAD, bench tools, cannibalized product hardware, quick-turn fabrication, AI-enabled workflows, and cross-functional collaboration to make ideas "real… real fast."Major Tasks and Responsibilities:Translate opportunity spaces, user insights, technical hypotheses, and early concepts into tangible models, rigs, breadboards, subsystems, and functional prototypes that accelerate speed to learning.Develop mechanical concepts for electro-mechanical and IoT-enabled pool equipment, including enclosures, mechanisms, fluid paths, sensors, actuators, thermal strategies, connectivity elements, cable routing, and manufacturable architectures.Choose the fastest credible prototyping method for the learning objective, including CAD, 3D printing, bench fabrication, machining, quick-turn suppliers, off-the-shelf components, test fixtures, and harvesting or cannibalizing parts from existing products.Use CAD appropriately for the phase of work: fast, fit-for-purpose early models when learning is the goal; robust parametric models, drawings, tolerance strategies, BOM inputs, and production documentation when concepts mature.Collaborate shoulder-to-shoulder with EE, firmware/software, IoT, test, industrial design, UX, product, manufacturing, sourcing, quality, and external partners to integrate mechanical, electrical, sensing, connectivity, and control elements into working systems.Define and run practical experiments to evaluate feasibility, usability, performance, reliability, serviceability, cost, and user experience; summarize learnings, risks, and recommendations so teams can make clear decisions quickly.Observe users, installers, service technicians, manufacturing partners, and field environments to identify unmet needs, human factors considerations, usability friction, and real-world constraints.Support transition from advanced engineering to NPD by converting validated prototypes into scalable product architectures, requirements, specifications, supplier direction, and development plans.Requirements:8+ years of mechanical engineering experience developing medium- to high-volume consumer, commercial, industrial, connected, or electro-mechanical products; pool, water treatment, automation, sensing, fluid handling, or outdoor equipment experience preferred.Strong mechanical fundamentals across mechanisms, enclosures, materials, sealing, thermal considerations, fluid handling, structural design, manufacturability, reliability, serviceability, and cost/performance tradeoffs.Demonstrated hands-on prototype development, experiment design, teardown, concept validation, and rapid iteration in ambiguous or early-stage environments.High proficiency with 3D CAD, preferably SolidWorks, plus broad familiarity with prototyping/fabrication methods including additive manufacturing, machining, bench fabrication, fixture design, quick-turn suppliers, and modification of existing hardware.Experience integrating electronics into mechanical systems, including electronics packaging, sensor/actuator mounting, thermal management, cable routing, sealing, strain relief, and service access.Ability to collaborate with electrical and firmware/software teams on connected or IoT-enabled prototypes; mechatronics, controls, robotics, automation, sensor integration, or light programming experience strongly preferred.Ability to perform engineering calculations, tolerance analysis, test planning, and practical data analysis; experience with structural, thermal, and/or flow simulation preferred; CFD a plus.Working knowledge of DFMEA/PFMEA, Voice of Customer, observational research/ethnography/dynamic interviews, human factors, technology readiness, root cause analysis, design verification, reliability testing, configuration management, and engineering change control.Familiarity with relevant compliance considerations for pool/spa or electro-mechanical products, such as UL, CSA, NSF, and related design/testing requirements.Strong written, verbal, and visual communication skills, including the ability to explain prototype learnings, risks, and decisions to technical and non-technical audiences.Preferred Qualifications, Education, and TravelExperience building functional prototypes that combine mechanical, electrical, firmware, data, app/cloud, or connected-device elements.Experience with industrial design partnership, human-centered design, field research, usability testing, installer/service technician research, or appliance-like consumer products.Comfort operating benchtop and fabrication tools, such as drill press, band saw, sander, hand tools, measurement tools, small mills/lathes, leak/pressure fixtures, lab instrumentation, and related equipment as appropriate to site procedures and safety training.B.S. in Mechanical Engineering or related engineering field required; M.S. in Mechanical Engineering, Mechatronics, Robotics, Product Design, Systems Engineering, or related field preferred.Role is based in person at Hayward's North Kingstown, RI center of excellence facility, with potential for up to 15% ad-hoc travel to Hayward sites, conferences, customer visits, or inspiration/validation activities.