BCI Mechanical Engineer — Rapid Prototyping & Production

Merge Labs; San Francisco (CA); On-site; USD 120,000 - 180,000; Full time

Job summary

Merge Labs seeks a Mechanical Engineer to own the physical architecture and packaging of our brain–computer interface hardware, spanning from early R&D prototypes to manufacturable product. You will bridge electrical performance, mechanical constraints, and manufacturing realities while delivering repeatable, high‑quality instrument subsystems.

You will collaborate with scientists and engineers to replace fragile setups with fixtures, alignment systems, calibration tools, and modular instrument

Qualifications

• Deep experience designing complex mechanical hardware.
• Strong fundamentals in tolerance analysis and material selection.
• Thermal design and system architecture expertise.
• Experience delivering manufacturable designs with vendor collaboration.
• Rapid prototyping mindset with instrument tooling capability.

Responsibilities

• Own mechanical lifecycle from napkin sketch to production.
• Design fixtures, jigs, mounts, and calibration tools for repeatable workflows.
• Lead thermal modeling and validation of compact electronic systems.
• Coordinate with Electrical, Industrial Design, and scientists.
• Establish acceptance criteria and document procedures for reproducibility.
• Set standards and manage vendor relationships for fabrication tooling.

Skills

Mechanical design

Thermal analysis

Tolerance analysis

Vendor management

Prototyping

Systems engineering

Tools

3D printing

CNC

Sheet metal

Job description

Merge Labs seeks a Mechanical Engineer to own the physical architecture and packaging of our brain–computer interface hardware, spanning from early R&D prototypes to manufacturable product. You will bridge electrical performance, mechanical constraints, and manufacturing realities while delivering repeatable, high‑quality instrument subsystems.

You will collaborate with scientists and engineers to replace fragile setups with fixtures, alignment systems, calibration tools, and modular instrument