Senior Mechanical Engineer (Continuous Improvement)

WHOOP; Boston (MA); On-site; USD 140,000 - 195,000; Full time

Job summary

WHOOP is seeking a Senior Mechanical Engineer to lead design improvements, validation strategy, and sustaining engineering for our flagship wearables. You will own mechanical subsystems, mentor junior engineers, and collaborate with cross-functional teams to deliver high-impact product changes at scale.

Based in Boston, MA, you will work with global suppliers and contract manufacturers, drive DOE and validation activities, and maintain CAD models and technical documentation to support

Qualifications

• Bachelor's or master's in Mechanical Engineering or related field.
• 5+ years designing, improving, and sustaining complex mechanical products.
• Strong experience with SolidWorks CAD and DFx/DfM feedback integration.
• Experience with high-volume manufacturing and working with contract manufacturers.

Responsibilities

• Own mechanical subsystems from concept through mass production.
• Lead design, analysis, and development to improve performance, reliability, manufacturability, and cost.
• Manage engineering changes with vendors and contract manufacturers for seamless production integration.
• Define and lead DOE and validation strategies to optimize product and manufacturing performance.
• Lead root cause investigations and drive resolution of quality, yield, and reliability issues in production.
• Maintain CAD models and technical documentation (3D/2D/BOMs/ECOs) for design changes and high-volume manufacturing.
• Mentor junior engineers and promote engineering best practices.
• Travel internationally up to 20% to support manufacturing partners and production builds.

Skills

Leadership

Mentoring juniors

Cross-functional collaboration

Root cause analysis

Problem solving

Education

BS or MS in Mechanical Engineering

Tools

SolidWorks CAD

Job description

At WHOOP, we're on a mission to unlock and inspire performance for life. WHOOP empowers users to perform at a higher level through a deeper understanding of their bodies and daily lives.

WHOOP is looking for a Senior Mechanical Engineer to lead and drive critical design improvements, validation strategy, and sustaining engineering efforts for our flagship wearable products at scale. You are a proactive, highly organized engineer with strong problem-solving skills and a sharp eye for detail. You thrive in a fast-paced, execution-driven environment and can drive creative mechanical solutions with independence and sound technical judgement. You will mentor junior engineers and collaborate cross-functionally with Electrical Engineering, Manufacturing, Supply Chain, Quality, and Program Management to deliver high-impact product improvements driven by customer feedback and evolving business needs. You will work closely with global suppliers and contract manufacturers to execute validation builds and drive and scale design changes in production environments, with a focus on high-quality deliverables, robust risk management, clear technical communication, and manufacturing stability. WHOOP operates with urgency because our mission demands it. We build products for people who push their limits—and we hold ourselves to the same standard. If you’re energized by complex challenges, cross-functional collaboration, and the opportunity to improve hardware products at scale, this role will push you—and reward you.

RESPONSIBILITIES:

• Complete technical ownership of mechanical subsystems and components for current generation WHOOP hardware products, driving improvements from concept through implementation in mass production
• Lead design, analysis, and development of mechanical solutions to improve product performance, reliability, manufacturability, and cost within existing production and design constraints
• Lead engineering change implementation with vendors and contract manufacturers, ensuring clear communication and seamless integration into production
• Define and lead DOE and validation strategies to optimize product and manufacturing performance
• Lead root cause investigations and drive resolution of quality, yield, and reliability issues in production
• Own and maintain CAD models and technical documentation (3D, 2D, BOMs, ECOs) to support design changes, validation, and high-volume manufacturing
• Mentor junior engineers and promote strong engineering best practices
• Travel internationally up to 20% to support manufacturing partners and production builds

QUALIFICATIONS:

• BS or MS in Mechanical Engineering or a related field
• 5+ years of experience in the design, improvement, and sustaining of complex mechanical products, preferably in consumer electronics, wearables, or medical devices
• 4+ years of SolidWorks CAD experience with best practices in part design, tolerance analysis, advanced assemblies, configuration management, and integration of DFx/DfM feedback
• 3+ years of experience working with Tier 1 and 2 contract manufacturers, including driving engineering changes and sustaining production in Asia and North America
• Demonstrated experience with high-volume manufacturing processes (e.g., injection molding, die casting, automated assembly), with a focus on yield, reliability, and cost optimization
• Strong experience in root cause analysis, failure investigation, and implementing design or process improvements in production environments
• Hands-on experience with prototyping and validation to support design changes and production improvements, along with experience in second sourcing, supplier qualification
• Experience leading cross-functional efforts and mentoring junior engineers
• Preferred experience with electromechanical systems, including integration of mechanical components with sensors, PCBs, and flex circuits in compact, high-volume products
• Experience developing and scaling automated test systems, complex fixtures, or production validation infrastructure preferred
• Preferred experience in wearable, health-focused, or other highly constrained consumer electronic products
• Experience leading engineering efforts in fast-paced or startup environments with high ownership and cross-functional influence
• Passion for health, human performance, and designing human-centered hardware preferred

This role is based in the WHOOP office located in Boston, MA. The successful candidate must be prepared to relocate if necessary to work out of the Boston, MA office.

WHOOP is an Equal Opportunity Employer and participates in E-verify to determine employment eligibility

The WHOOP compensation philosophy is designed to attract, motivate, and retain exceptional talent by offering competitive base salaries, meaningful equity, and consistent pay practices that reflect our mission and core values.

At WHOOP, we view total compensation as the combination of base salary, equity, and benefits, with equity serving as a key differentiator that aligns our employees with the long-term success of the company and allows every member of our corporate team to own part of WHOOP and share in the company’s long-term growth and success.

The U.S. base salary range for this full-time position is $140,000-$195,000. Salary ranges are determined by role, level, and location. Within each range, individual pay is based on factors such as job-related skills, experience, performance, and relevant education or training.

In addition to the base salary, the successful candidate will also receive benefits and a generous equity package.

These ranges may be modified in the future to reflect evolving market conditions and organizational needs. While most offers will typically fall toward the starting point of the range, total compensation will depend on the candidate’s specific qualifications, expertise, and alignment with the role’s requirements.