Senior Mechanical Engineer – Sleep Systems & Thermal Lead

Orion Sleep; San Francisco (CA); On-site; USD 150,000 - 210,000; Full time

Job summary

Orion Sleep in San Francisco develops intelligent sleep technology and seeks a Senior Mechanical Engineer to own critical mechanical systems across the Orion Sleep System, from concept to mass production.

This hands-on technical leadership role spans thermal systems, enclosures, CMF, and high-precision assemblies, collaborating with global manufacturing partners and cross-functional teams.

Qualifications

• 7-10+ years of mechanical engineering experience in consumer hardware or integrated electromechanical systems.
• Proven system-level ownership across complex mechanical architectures.
• Deep expertise in plastics, sheet metal, mechanisms, thermal systems, and high-volume manufacturing.
• Expert-level CAD proficiency (SolidWorks or equivalent) with strong DFM/DFA and GD&T skills.
• Track record of taking products from concept to EVT, DVT, PVT, and MP.
• Hands-on engineering mindset - comfortable in labs, factories, and design reviews.
• Strong technical communication and ability to influence across teams without direct authority.
• Experience with thermoelectric (TEC/Peltier) systems or thermal-regulation platforms is a plus.
• Experience working with Asian contract manufacturers is a plus.
• Strong sensitivity to CMF and cosmetic quality standards is a plus.

Responsibilities

• Lead design of TEC-based thermal systems, fluid routing, enclosures, and integrated mechanical assemblies across the Orion Sleep System.
• Own detailed CAD, tolerancing, GD&T, and stack-up analysis.
• Drive CMF alignment, surface quality, and tooling readiness.
• Translate system requirements into robust, production-ready mechanical designs.
• Work directly with global manufacturing partners across plastics, sheet metal, machining, and final assembly.
• Guide tooling development, design changes, and build readiness for EVT / DVT / PVT and MP.
• Support on-site factory builds, failure analysis, and process optimization.
• Define and execute validation plans for durability, lifecycle reliability, thermal stability, noise, fit, and cosmetic quality.
• Partner with Reliability, QA, and Operations to drive root‑cause analysis and corrective actions.
• Maintain drawings, specifications, ECOs, and build documentation.
• Collaborate closely with EE and FW on system integration, routing constraints, and sensor placement.
• Partner with Product, Ops, and Supply Chain to balance cost, schedule, and manufacturability.
• Lead design reviews and technical trade-offs with clarity and ownership.

Skills

Mechanical engineering

System-level ownership

CAD proficiency

DFM/DFA

GD&T

Thermal systems

High-volume manufacturing

Tools

SolidWorks

Job description

Orion Sleep in San Francisco develops intelligent sleep technology and seeks a Senior Mechanical Engineer to own critical mechanical systems across the Orion Sleep System, from concept to mass production.

This hands-on technical leadership role spans thermal systems, enclosures, CMF, and high-precision assemblies, collaborating with global manufacturing partners and cross-functional teams.