Senior Development Engineer for Helmets & Hard Parts

Polaris Inc.; Rigby (ID); On-site; USD 120,000 - 160,000; Full time

Job summary

Polaris Inc. in Rigby, ID is seeking a Staff (Lead) Development Engineer to provide technical leadership across the full product development lifecycle for helmet and hard-parts focused products.

You will create detailed 3D CAD models, apply DFMA practices, and build/test prototypes using 3D printing, CNC, thermoforming and molding methods to validate concepts and designs before launch.

Qualifications

• Bachelor’s degree in Mechanical Engineering.
• Minimum of 10 years of product development experience.
• Expert-level CAD modeling skills, including surface modeling.
• Experience with SOLIDWORKS and/or Creo.
• Ability to independently manage complex technical projects and make sound engineering decisions with limited direction.
• Strong understanding of manufacturing methods such as plastic injection molding, advanced composite manufacturing, extrusion molding, metal casting, metal injection molding, heat staking, and gluing.
• Extensive hands-on prototyping experience using methods such as 3D printing, CNC machining, thermoforming, silicone molding, and resin casting.
• Advanced experience with product testing, performance validation, and analysis.
• Demonstrated success developing products from initial concept through production.

Responsibilities

• Drive the mechanical design and development of helmets and other hard parts and accessories from concept through production.
• Create detailed 3D CAD models and assemblies that communicate product function, design intent, and manufacturability.
• Apply advanced design for manufacturing and design for assembly practices to support high-quality, cost-effective production across a range of manufacturing processes.
• Build and test prototypes using methods such as 3D printing, CNC machining, thermoforming, silicone molding, resin casting, and other shop tools to validate concepts and product function.
• Design and execute product testing protocols using custom fixtures, sensors, and data acquisition tools to evaluate performance and durability.
• Use test data and field feedback to evaluate, iterate, and improve designs before launch.
• Coordinate with suppliers and manufacturing partners to support product development, technical problem-solving, and a smooth transition to mass production.
• Collaborate with industrial design, product management, sourcing, factory engineering, and other internal stakeholders to align on performance, timeline, and brand goals.
• Manage multiple projects simultaneously while balancing hands-on engineering work, documentation, planning, and communication.
• Provide technical guidance and support to engineers and cross-functional team members as needed.

Skills

CAD modeling

Surface modeling

3D CAD

Prototyping

Data-driven testing

Education

Bachelor’s degree in Mechanical Engineering

Tools

SOLIDWORKS

Creo

3D printing

CNC machining

Job description

Polaris Inc. in Rigby, ID is seeking a Staff (Lead) Development Engineer to provide technical leadership across the full product development lifecycle for helmet and hard-parts focused products.

You will create detailed 3D CAD models, apply DFMA practices, and build/test prototypes using 3D printing, CNC, thermoforming and molding methods to validate concepts and designs before launch.