Lead Wearable Mechanical Engineer – Comfort & CAD Expert

OSI Engineering, Inc.; San Francisco (CA); Hybrid; USD 150,000 - 180,000; Full time

Benefits offered by this job

401(k) with match

health insurance

flexible PTO

Job summary

OSI Engineering, Inc. is seeking an experienced Senior Product/Mechanical Design Engineer to own the end-to-end design of our wearable neurotech product.

You will shape the look, feel, comfort, and performance for daily wear, from sketches to shipped hardware. You will lead integration of electronics into soft goods, optimize weight and thermal management, and drive DfM with contract manufacturers while building an in-house product design function over time.

Qualifications

• 10+ years in product design and/or mechanical engineering, with multiple shipped consumer wearables or body-worn products.
• Hands-on experience integrating electronics into soft goods (headwear, apparel, garments, or fabric-heavy wearables).
• Expert CAD (SolidWorks, Fusion 360, Rhino, or equivalent) and rendering (KeyShot or similar).
• Comfort engineering backed by structured wear testing: pressure points, weight, thermal, and fit across diverse users.
• DfM, tooling, and quality work with overseas CMs.

Responsibilities

• Own industrial and mechanical design end-to-end: sketches, CAD, prototypes, tooling, and DfM with overseas contract manufacturers
• Package electronics into soft goods: flex PCB and rigid-island placement, textile-to-rigid transitions, weight distribution, thermal management, and serviceability
• Define and validate comfort through pressure mapping, weight balance, skin-contact thermal limits, breathability, and long-wear testing across head sizes and hair types
• Set the product’s design language and materials: fabrics, seams, transitions, and how much the device stands out or blends in
• Work with the EE, audio, and camera leads on antenna keep-outs, electrode contact pressure, acoustic ports, mic mesh, and lens windows
• Work with reliability on drop, ingress, thermal, and ergonomic robustness
• Lead the external textile, mechanical, and electronics CM teams, then build out the in-house product design function as it grows

Skills

Product design

Mechanical engineering

CAD

Rendering

Comfort engineering

DfM

Tools

SolidWorks

Fusion 360

Rhino

KeyShot

Job description

OSI Engineering, Inc. is seeking an experienced Senior Product/Mechanical Design Engineer to own the end-to-end design of our wearable neurotech product.

You will shape the look, feel, comfort, and performance for daily wear, from sketches to shipped hardware. You will lead integration of electronics into soft goods, optimize weight and thermal management, and drive DfM with contract manufacturers while building an in-house product design function over time.