Senior Mechanical Engineer

LLume is developing wearable technology that measures breathing, movement, and performance in real time using our patented Light Lace® fiber-optic sensing platform. Our compact sensor pod integrates optics, electronics, sensing, and wireless connectivity into a wearable form factor designed for comfort and minimal distraction.

What You’ll Own

• Lead the transition from prototype and low-volume builds into repeatable, high-volume production.
• Develop manufacturing strategies for compact enclosures containing optical, electronic, and mechanical components.
• Design and validate waterproofing systems using gaskets, adhesives, welded joints, membranes, conformal coatings, encapsulation, and electronic potting.
• Develop scalable potting and coating processes, including material selection, dispensing, masking, surface preparation, cure control, coverage inspection, and leak testing.
• Evaluate waterproofing materials for adhesion, flexibility, thermal performance, chemical resistance, optical compatibility, reworkability, and long-term reliability.
• Prevent and resolve defects such as voids, bubbles, incomplete coverage, delamination, contamination, and moisture ingress.
• Drive DFM/DFA, tolerance analysis, material selection, tooling, assembly methods, and production documentation.
• Select and qualify manufacturing partners, equipment, processes, fixtures, and suppliers.
• Lead pilot builds and production ramp, resolving yield, quality, throughput, reliability, and field-performance issues.
• Create verification and validation plans covering ingress protection, leak testing, drop, vibration, thermal cycling, humidity, sweat, corrosion, UV exposure, and mechanical durability.
• Own testing and evaluation from engineering prototypes through EVT, DVT, PVT, certification, and sustained production.
• Coordinate with accredited laboratories and manufacturing partners on applicable certifications and compliance testing, including IP ratings, FCC, CE, UL/CSA, RoHS, and REACH.
• Establish critical-to-quality requirements, PFMEAs, control plans, work instructions, inspection methods, and acceptance criteria.
• Improve unit cost, cycle time, yield, and capacity through data-driven process development.
• Work closely with mechanical, electrical, firmware and product teams.

What We’re Looking For

• 7+ years of experiencein manufacturing engineering, NPI, process engineering, product validation, or a related hardware role.
• Proficiency in Computer-Aided Design (CAD) tools for 3D modeling, detailed drawings, and assembly design (e.g., Fusion 360, SolidWorks, Creo, or similar).
• Demonstrated ownership of scaling an electromechanical or optoelectronic product from prototypes or hundreds of units into the thousands or tens of thousands.
• Hands‑on experience with potting compounds, encapsulants, and conformal coatings used to waterproof electronics and optoelectronic assemblies.
• Working knowledge of silicone, urethane, epoxy, acrylic, and parylene systems and their manufacturing tradeoffs.
• Experience specifying and validating manual or automated dispensing, coating, curing, masking, and inspection processes.
• Strong experience with waterproof or water‑resistant product design, enclosure sealing, ingress testing, and root‑cause analysis of leaks.
• Experience developing certification strategies and working with independent test laboratories, notified bodies, or regulatory consultants.
• Deep knowledge of environmental, mechanical, reliability, and production testing and evaluation.
• Experience manufacturing precision plastic or metal enclosures using injection molding, CNC machining, die casting, or sheet‑metal fabrication.
• Familiarity with optical alignment, adhesives, fiber routing, sealing, fastening, and sensitive‑component handling.
• Strong knowledge of GD&T, tolerance stack‑ups, manufacturing drawings, fixtures, and inspection methods.
• Experience working directly with contract manufacturers, toolmakers, and component suppliers.
• Practical experience with DOE, process capability, measurement‑system analysis, root‑cause analysis, and yield improvement.
• A hands‑on mindset and comfort operating in a fast‑moving startup environment.

Especially Valuable

• Experience with wearable devices, consumer electronics, medical devices, photonics, or compact sensing products.
• Experience achieving IPX7, IP67, or similar ingress‑protection ratings.
• Knowledge of pressure‑decay, vacuum‑decay, immersion, tracer‑gas, or other production leak‑testing methods.
• Familiarity with coating‑thickness measurement, adhesion testing, cure verification, and environmental‑aging studies.
• Experience ensuring that coatings and potting materials do not interfere with optical paths, connectors, sensors, antennas, heat transfer, or serviceability.
• Experience building automated production‑test systems and product traceability.
• Lean, Six Sigma, supplier‑quality, reliability, or regulatory‑certification credentials.

Why LLume

This is an opportunity to define how an innovative optoelectronic product is built, not simply maintain an established production line. You’ll have significant ownership and create the processes, testing systems, and supplier relationships that enable LLume’s next stage of growth.