Mechanical Engineer

Evolve; Austin (TX); On-site; USD 90,000 - 130,000; Full time

Job summary

Evolve is seeking a Mechanical Engineer to design and deliver hardware systems for our next-generation VR headset. You will work at the intersection of design, electrical integration, and human factors to create robust, manufacturable solutions.

You will own mechanical design and product architecture, prototype through production, and partner with cross-functional teams to balance comfort, performance, and reliability.

Qualifications

• 4–8 years of mechanical engineering experience in consumer electronics, wearables, or similar products.
• Experience designing and shipping products with tight integration between mechanical, electrical, and user-facing systems.
• Strong CAD skills (SolidWorks, NX, Creo, or equivalent).
• Experience with tolerance analysis and mechanical stack-ups.
• Hands-on experience with prototyping, assembly, and debugging physical hardware.
• Experience working through at least one full product development cycle (prototype → production).
• Strong Materials Science background surrounding soft systems, wearable electronics.

Responsibilities

• Design mechanical systems and assemblies for VR headsets, including enclosures, frames, and mounting.
• Optimize thermal management and strap/fit systems for comfort and reliability.
• Collaborate with Electrical, Firmware, and Software teams to integrate displays, optics, and power.
• Drive rapid prototyping from concept to EVT, including 3D-printed parts and soft tooling.
• Validate designs through fit, finish, and functional testing; resolve tolerance and durability issues.
• Partner with suppliers to ensure DFM/DFA and scaling to production.

Skills

Cross-functional collaboration

Hands-on prototyping

Problem solving

Ability to work through ambiguity

Tools

SolidWorks

NX

Creo

Job description

Evolve is an innovative, consciousness-focused company developing a groundbreaking VR platform that integrates multimodal physiological signals (including but not limited to EEG, PPG, EDA, IMU, eye tracking, etc.) to deliver personalized biofeedback experiences. Our mission is to help users develop deeper self-awareness, regulate emotions, and enhance cognitive performance.

Evolve is seeking a Mechanical Engineer to design and deliver critical hardware systems for our next-generation VR headset platform. This role sits at the intersection of industrial design, electrical integration, and human factors, with direct responsibility for mechanical architectures that impact comfort, sensor performance, manufacturability, and overall product reliability.

This is not a pure CAD or sustaining role. The ideal candidate has experience building and shipping complex consumer electronics or wearable devices, and is comfortable working through ambiguity, rapid iteration, and cross-functional integration challenges.

What You’ll Own

1. Mechanical Design & Product Architecture

• Design mechanical systems and assemblies for VR headsets, including:
• Enclosures and structural frames
• Optical/sensor mounting systems
• Thermal management solutions
• Strap and fit systems
• Contribute to overall product architecture, balancing:
• Comfort and ergonomics
• Structural integrity
• Thermal and electrical constraints
• Create 3D models, detailed drawings, and tolerance analyses for production-ready designs

2. Cross-Functional Hardware Integration

• Work closely with Electrical, Firmware, and Software teams to integrate:
• Displays and optics
• Batteries and power systems
• Resolve integration challenges involving:
• Sensor placement and signal quality
• EMI/EMC and grounding considerations
• Cable routing and connector reliability
• Participate in system-level tradeoffs across mechanical, electrical, and user experience domains

3. Prototyping, Build & Validation

• Drive rapid prototyping from early concept through EVT builds:
• 3D printed assemblies
• Soft tooling and early production processes
• Support build cycles (Proto, EVT, DVT), including:
• Hands-on assembly and debug
• Fit, finish, and functional validation
• Identify and resolve issues related to:
• Mechanical tolerances
• Assembly variation
• Structural or durability failures

4. DFM, Manufacturing & Supplier Engagement

• Design for manufacturability (DFM), assembly (DFA), and cost at scale
• Work with suppliers and contract manufacturers to:
• Refine tooling strategies
• Review mold flow, tolerance stack-ups, and yield risks
• Support transition from EVT → DVT → PVT with increasing design maturity
• Evaluate and implement “steel-safe” changes where needed
• Design for long-duration wear:
• Fit adjustability
• Skin-contact materials
• Partner with research and product teams to iterate on:
• Comfort vs. sensor performance tradeoffs
• Strap tension vs. signal quality interactions
• Validate designs through user testing and feedback loops

Required Experience

• 4–8 years of mechanical engineering experience in consumer electronics, wearables, or similar products
• Experience designing and shipping products with tight integration between mechanical, electrical, and user-facing systems
• Strong CAD skills (e.g., SolidWorks, NX, Creo, or equivalent)
• Experience with tolerance analysis and mechanical stack-ups
• Hands-on experience with prototyping, assembly, and debugging physical hardware
• Experience working through at least one full product development cycle (prototype → production)
• Strong Materials Science background surrounding soft systems, wearable electronics

Preferred Experience

• Experience working on VR/AR headsets or wearable devices
• Experience integrating sensors (optical, biosignal, or motion sensing) into physical products
• Familiarity with:
• Injection molding, soft goods, and overmolding
• Thermal management in compact devices
• Experience working with contract manufacturers (CMs/JDMs)
• Exposure to EVT/DVT/PVT build cycles and production ramp

What Success Looks Like

• Delivers robust mechanical designs that hold up across EVT and into DVT with minimal rework
• Anticipates integration challenges early and drives cross-functional solutions
• Balances comfort, performance, and manufacturability without over-indexing on one dimension
• Operates effectively in a fast-paced, iterative environment with evolving requirements