Mechanical Engineer

Cogwear, Inc.; Saint Paul, Northern (MN, KY); Hybrid; USD 90,000 - 140,000; Full time

Job summary

Cogwear, Inc. is seeking an experienced Mechanical Engineer to join a multidisciplinary team developing a next-generation EEG headband.

You will own the mechanical architecture, focusing on comfort, durability, and high-volume manufacturability to deliver clinical-grade signal quality. You will collaborate with electrical, biomedical, industrial design, and data science teams to optimize electrode integration, housing, and thermal management while supporting regulatory readiness and validation

Qualifications

• Bachelor's or Master's degree in Mechanical Engineering.
• 5+ years of mechanical design experience, preferably in consumer hardware.
• Proficiency in CAD tools (SolidWorks, Creo, or equivalent).
• Knowledge of DFM/DFA principles and manufacturing processes.
• Experience with rapid prototyping and iterative hardware development.

Responsibilities

• Design and develop the mechanical architecture of a wearable EEG headband system.
• Develop ergonomic designs optimized for comfort, stability, and signal integrity across head shapes and movement.
• Engineer mechanisms for consistent electrode-to-scalp contact while minimizing pressure points.
• Integrate electronics housings, battery systems, and cabling into compact wearables.
• Design dynamic fit systems and address skin-contact interface challenges.

Skills

Mechanical design

Cross-functional collaboration

Ergonomics

Project planning

Hardware development

Education

Bachelor's or Master's in Mechanical Engineering

Tools

SolidWorks

Creo

DFM/DFA

Job description

Will Report To: Director of Engineering / Product Development

Industry: Medical Devices / Wearable Neurotechnology

We are seeking an experienced Mechanical Engineer to join a multidisciplinary team developing a next-generation EEG headband designed to capture high-fidelity neurological signals across applications in medical diagnostics, consumer insights, and sports performance optimization.

This role focuses on the mechanical architecture, ergonomics, and manufacturability of a wearable neurotechnology platform that must deliver clinical-grade signal quality while remaining comfortable, durable, and scalable for high-volume production.

The Mechanical Engineer will collaborate closely with electrical engineers, biomedical engineers, industrial designers, and data scientists to design and optimize a device that integrates dry or hybrid EEG electrodes, electronics, thermal management, structural elements, and user-facing ergonomic features.

This position is ideal for engineers passionate about human-centered hardware, wearable technology, and advanced biosensing systems.

Key Responsibilities

Product Mechanical Design

Design and develop the mechanical architecture of a wearable EEG headband system, including structural frames, electrode mounting mechanisms, and adjustment systems.

Develop ergonomic designs optimized for comfort, stability, and signal integrity across diverse head shapes and movement conditions.

Engineer mechanisms for consistent electrode-to-scalp contact while minimizing pressure points and motion artifacts.

Integrate electronics housings, battery systems, and cabling pathways into compact wearable form factors.

Wearable System Engineering

Design dynamic fit systems (spring-loaded elements, flexible frames, adjustable tension mechanisms).

Address biomechanics and skin-contact interface challenges for extended wear.

Optimize weight distribution and mechanical compliance for sports and high-motion environments.

Collaborate on sensor placement and electrode alignment to maximize signal acquisition quality.

Materials and Manufacturing

Select and validate biocompatible and skin-safe materials suitable for prolonged contact.

Develop designs compatible with high-volume manufacturing processes, including:

• Overmolding
• Flexible polymers
• Precision machining
• Conduct Design for Manufacturability (DFM) and Design for Assembly (DFA) analysis.

Prototyping & Testing

Build and evaluate rapid prototypes using 3D printing, soft tooling, and iterative hardware builds.

Conduct mechanical validation testing, including:

• Durability and fatigue
• Sweat and environmental exposure
• Drop and impact resistance
• Fit and comfort trials

Support human factor and usability studies.

Cross-Functional Collaboration

Work closely with:

• Electrical engineering (PCB and sensor integration)
• Biomedical engineering (EEG electrode performance)
• Industrial design (aesthetics and usability)
• Data science teams (signal quality optimization)

Participate in design reviews, risk analysis, and product roadmap planning.

Regulatory & Quality Support

Support development in compliance with medical device standards and regulatory frameworks, including:

• ISO 13485
• IEC safety standards

Contribute to documentation, design history files, and validation protocols.

Cross-functional collaboration with neuroscience, firmware, data science, mechanical engineering, and regulatory teams

Rapid prototyping and iteration cycles

Innovation-driven culture with high ownership and technical depth

Mission-focused: advancing neurotechnology accessibility

Required Qualifications

Bachelor's or Master's degree in Mechanical Engineering

5+ years of mechanical design experience, preferably in:

• Consumer hardware
• Proficiency in CAD tools (SolidWorks, Creo, or equivalent).
• Knowledge of DFM/DFA principles and manufacturing processes.
• Experience with rapid prototyping and iterative hardware development.

Preferred Qualifications

• Experience designing wearable biosensing devices (EEG, EMG, ECG, or other physiological sensors).
• Knowledge of human factors engineering and ergonomics.
• Experience with flexible materials and soft goods integration.
• Familiarity with biocompatibility requirements and skin-contact materials.
• Experience with sports performance devices or consumer wearables.
• Background working in startup or innovation-driven R&D environments.

The Mechanical Engineer will play a pivotal role in bringing a new class of wearable neurotechnology to market - unlocking insights into brain function for healthcare, cognitive performance, and human optimization.

The brain is the next frontier in human progress. Cogwear is a brain technology company that promotes human health, peace, and performance by making neurodata more accessible.

The company provides wearable, AI-powered technology for customized healthcare and consumer products, research, and other applications that require high-fidelity, on-demand neurodata outside of a clinical setting.

Cogwear offers a technology platform that brings together a headband, app, and algorithms to directly and accurately measure brain signals, anywhere, any time - turning data into insights that help people and enterprises reach greater potential than ever before.

Cogwear's commercial partnerships make it a pioneer in neuro-based products across a range of areas from athletic safety and CTE screening to advertising optimization and customer experience. The company is pursuing FDA clearance and continues to develop its technology to help tackle pressing health issues, including Alzheimer's Disease, pediatric epilepsy, and mental healthcare.