Mechanical Design Engineer

PassFort; Greater London; On-site; GBP 80,000 - 120,000; Full time

Benefits offered by this job

Equity options

Travel to New York for R&D

Job summary

Level Zero is building next‑gen biosensor technology for real‑time biomarker monitoring. We seek a hands‑on mechanical engineer to own plastic component design for wearable pump systems, from concept to production, using robust CAD models and tolerance analysis.

You will lead verification efforts, work with suppliers, and contribute to early‑stage R&D in a dynamic startup environment. The role requires a Master’s degree in biomedical/mechanical engineering or related field and 2–4 years of

Qualifications

• Master’s degree in biomedical or mechanical engineering or related field.
• 2–4 years of industry experience with biomedical devices preferred.
• Experience designing pump systems and fluid handling mechanisms.
• Excellent CAD and drafting skills with complex assemblies.
• Knowledge of GD&T, tolerancing, and manufacturing tolerances.
• Experience with DFMEA/PFMEA and risk management.
• Experience with DFMA principles and external vendors.
• Experience with PLM systems and design documentation.
• Strong root-cause analysis and problem solving.
• Experience in V&V testing and design verification plans.

Responsibilities

• Own mechanical design of plastic components for wearable device and pump system.
• Design injection moulded parts from concept to production release.
• Create high-quality 3D CAD models, assemblies, drawings to standards.
• Perform tolerance analysis and prepare design specs and requirements.
• Develop verification test methods and conduct tests; iterate designs from data.
• Lead mechanical investigations to find root causes and implement fixes.
• Apply human-centered design through usability studies and user research.
• Collaborate with suppliers and manufacturing partners for production readiness.
• Specify and qualify bought-in components and integrate into product.
• Coordinate with electronics, QA, manufacturing, and industrial design teams.
• Balance performance, usability, reliability, manufacturability and cost.
• Contribute to early-stage R&D and future design iterations.

Skills

Master’s degree in Biomedical/Mech Eng

2-4 years industry experience

User-centered design

Pump systems/ fluid handling

Injection moulded plastics design

CAD & drafting (complex assemblies)

Tolerance analysis & GD&T

DFMEA/PFMEA

DFMA/DFM principles

External supplier/manufacturer liaison

PLM systems

Root cause analysis

V&V testing design & execution

Quality standards knowledge (ISO 13485

Prototype development (rapid protos)

joint teams collaboration

Education

Master’s degree in biomedical/mechanical engineering or related

Tools

PLM systems

3D CAD modelling

GD&T drafting tools

Job description

About Level Zero

Level Zero is pioneering next-generation biosensor technology for precise, real-time monitoring of critical endocrine biomarkers. Recognised as one of the top 20 startups across all categories worldwide at TechCrunch Disrupt 2024 - and backed by top‑tier organisations like Redalpine, SOSV, and Entrepreneur First - we’re pushing the boundaries of biochemistry and nanotechnology to revolutionise personalised health.

Founded by two seasoned engineers, we bring extensive experience in R&D, technical innovation, and commercial strategy to transform the way people monitor their health. Our mission is bold: to revolutionise health management by delivering clinical‑grade data directly to individuals, wherever they are.

We’re seeking driven innovators to join us in pushing the boundaries of biosensing and health tech, making personalised health monitoring a reality for everyone. To achieve this ambitious vision, we’re assembling the best team in the world - dedicated to turning cutting‑edge science into life‑changing, real‑world solutions.

What You’ll Do

• Own the mechanical design and development of plastic components for a wearable device and pump system
• Design robust injection moulded plastic parts from concept through to production release
• Produce high‑quality 3D CAD models, assemblies and engineering drawings to manufacturing standards
• Perform tolerance analysis and tolerance stack‑ups to ensure robust product performance and manufacturability. Create detailed design specifications, engineering requirements and mechanical architecture documentation
• Develop, refine and execute verification test methods to evaluate product performance and reliability. Plan and conduct engineering testing, analyse results and iterate designs based on data
• Lead mechanical investigations, identify root causes of failures and implement effective design improvements
• Apply human‑centered design practices by conducting human factors studies, usability evaluations, and user research sessions - translating findings into actionable product and design improvements
• Work closely with external suppliers and manufacturing partners to develop production‑ready components
• Specify and qualify bought‑in components and work with suppliers to integrate them into the product
• Collaborate closely with electronics, systems, quality, manufacturing and industrial design teams
• Balance technical performance, usability, reliability, manufacturability and cost throughout the design process
• Contribute to early‑stage R&D, collaborating with engineering leadership to define and refine future design iterations

What You Bring

The ideal candidate must have:

• Master’s degree with 2-4 years of industry experience, in biomedical engineering, mechanical engineering or a related discipline
• Experience designing products with user needs at the centre of development
• Experience designing pump systems, valves, diaphragms or other fluid handling mechanisms. Experience designing leak‑tight assemblies and developing leak test methods
• Excellent CAD & drafting skills including complex assemblies and surfacing where appropriate with strong understanding of engineering drawings, GD&T and manufacturing tolerances
• Experience performing tolerance stack analysis and applying statistical tolerancing where appropriate
• Experience creating engineering documentation including design specifications and product requirements. Experience applying DFM, DFA and DFMA principles. Experience working with external suppliers, manufacturers and tooling vendors
• Experience creating and refining mechanical test methods and verification plans
• Experience with DFMEA, PFMEA and structured engineering risk management
• Strong experience designing injection moulded plastic components for volume manufacture. Experience attending tooling trials, evaluating moulded parts and resolving manufacturing issues
• Proven ability to troubleshoot mechanical failures using structured root cause analysis
• Understanding of assembly methods including snap fits, heat staking, ultrasonic welding, adhesives or overmoulding
• Experience with engineering change control, product release processes and PLM systems
• Strong communication skills and ability to work within multidisciplinary engineering teams
• Comfortable taking ownership of significant subsystems while working with appropriate technical guidance

Nice to have

• Experience with design of devices for extraction of dermal interstitial fluid
• Experience designing wearable medical devices
• Knowledge of ISO 13485, ISO 14971 or equivalent quality systems
• Experience with verification and validation (V&V) testing
• Experience with reliability, environmental, fatigue or life‑cycle testing
• Experience designing precision mechanical mechanisms
• Experience working with miniature or highly integrated assemblies
• Experience with rapid prototyping, machining and 3D printing
• Familiarity with Design of Experiments (DOE) and statistical data analysis
• Experience supporting pilot builds, manufacturing scale‑up and production transfer
• Basic FEA experience for structural or thermal assessment
• Prior work in a start‑up or small company environment
• Prior work in medical device development

Who You Are

We value culture as much as we value technical expertise, creating an environment that’s equal parts collaboration, curiosity, and fun.

We’re a fast‑paced, mission‑driven young team on a quest to make a lasting impact, fueled by uncompromising integrity, unwavering support for one another, and the thrill of exploring uncharted territories. Our passion for excellence drives everything we do, and we welcome individuals who share our commitment to shaping the future.

If our vision excites you, here are the qualities we look for:

• You live and breathe integrity, tackling challenges with honesty and transparency
• You’re a self‑starter who loves diving into the unknown, collaborating on complex problems, and taking full ownership of results
• You excel at open, clear communication and see every piece of feedback as a springboard for growth—especially in a science and data‑focused environment
• You’re motivated by creating real impact, particularly when it comes to advancing human health
• You strike a balance between independence and collaboration, knowing when to seek support or invite others to join in
• You’re confident in defending your ideas, while also valuing respectful, constructive debate as a path to better solutions
• You thrive in the dynamic atmosphere of a startup, constantly evolving your skill set and fearlessly applying what you learn

What We Offer

• A full‑time role with a competitive salary and equity options, reflecting our value in your expertise and potential
• An environment where you’ll collaborate directly with the founding team at a leading biosensor startup, gaining access to industry experts and thought leaders
• The chance to grow with us, including ample opportunities for leadership, career advancement, and exploration
• Travel to New York and other potential sites for R&D purposes
• The excitement of working on cutting‑edge technology, shaping strategic decisions, and driving innovation at an early‑stage venture alongside a superstar team

Be Part of Our Journey

If you’re ready to be at the forefront of biosensing innovation and thrive in fast‑paced, learning‑rich environments, we’d love to hear from you.

If your skills and experience do not align perfectly with this role, yet you believe you have something unique to offer, we’re keen to listen. Reach out to us with a short statement on how you can contribute and let’s discuss where you might fit into our team.