Mechanical Engineer, BCI Hardware & Rapid Prototyping

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

Job summary

Merge Labs is seeking a Mechanical Engineer to own the physical architecture of BCI hardware, from early R&D prototypes to product-ready systems. You will bridge electrical performance, mechanical constraints, and manufacturing realities while building repeatable fixtures, calibration tools, and instrument subsystems.

Own the full mechanical lifecycle and vendor relations. You will work closely with scientists to replace fragile setups with fixtures and tooling that save time and improve data

Qualifications

• Bachelor's degree in Mechanical Engineering or equivalent.
• Proven track record in designing complex mechanical hardware and taking designs through build, test, and production turns.
• Strong fundamentals in tolerance analysis, materials/process selection, thermal design, mechanical architecture, and design verification.

Responsibilities

• Drive the mechanical architecture and packaging of high-density PCBA s and related hardware.
• Execute rapid fabrication methods to validate form, fit, and function.
• Own thermal modeling and validation for compact systems.
• Design instrumentation and tooling to turn setups into repeatable workflows.
• Define acceptance criteria and document procedures for reproducibility.
• Oversee transition from prototype to production with EVT/DVT/PVT and tooling development.
• Collaborate with EE, software, industrial design, clinical and scientists to meet performance and usability goals.
• Establish rigorous testing protocols for mechanical reliability and repeatability.

Skills

Mechanical design

Thermal design

Tolerance analysis

DFM/DFA

Prototype tooling

Vendor collaboration

3D printing

CNC

Sheet metal

Education

Bachelor's degree in Mechanical Engineering

Tools

3D printing

CNC

Sheet metal

Job description

Merge Labs is seeking a Mechanical Engineer to own the physical architecture of BCI hardware, from early R&D prototypes to product-ready systems. You will bridge electrical performance, mechanical constraints, and manufacturing realities while building repeatable fixtures, calibration tools, and instrument subsystems.

Own the full mechanical lifecycle and vendor relations. You will work closely with scientists to replace fragile setups with fixtures and tooling that save time and improve data