Mechanical Engineer, BCI Hardware & Prototyping

Merge; San Francisco, Northern (CA, KY); Hybrid; USD 120,000 - 190,000; Full time

Job summary

Merge Labs in San Francisco is seeking a Mechanical Engineer to own the physical architecture and packaging of our brain-computer interface systems, spanning R&D prototypes to product-ready hardware.

You will bridge electrical performance, thermal constraints, manufacturing realities, and experimental workflows, designing tooling and fixtures to make scientists more productive while preparing designs for EVT/DVT/PVT transitions.

Qualifications

• Proven track record in complex mechanical hardware design.
• Experience moving designs from prototype to production.
• Strong understanding of thermal management and packaging.
• Ability to work with cross-functional teams and vendors.

Responsibilities

• Drive mechanical architecture and packaging of high-density PCBs and assemblies.
• Perform rapid fabrication using 3D printing, CNC, and sheet metal.
• Own thermal modeling and validation for compact systems.
• Design fixtures, jigs, and tooling for repeatable workflows.
• Define performance criteria and document procedures for reproducibility.
• Support EVT/ DVT to production transitions with vendors.

Skills

Mechanical design

Thermal management

DFM/DFX

Vendor collaboration

3D CAD

Education

Bachelor's degree in Mechanical Engineering

Tools

3D printing

CNC machining

Job description

Merge Labs in San Francisco is seeking a Mechanical Engineer to own the physical architecture and packaging of our brain-computer interface systems, spanning R&D prototypes to product-ready hardware.

You will bridge electrical performance, thermal constraints, manufacturing realities, and experimental workflows, designing tooling and fixtures to make scientists more productive while preparing designs for EVT/DVT/PVT transitions.