Sr. Staff Engineer, Mechanical Design

Ayar Labs, Inc.; San Jose (CA); On-site; USD 150,000 - 180,000; Full time

Job summary

Ayar Labs is seeking a hands-on Sr. Staff Engineer in San Jose to own the mechanical realization of our co-packaged optics products. You will drive 3D modeling, drawings, tolerancing, and production-ready designs, collaborating with EE and photonics teams and working with CM partners on tooling and fixtures.

The role requires a BS in Mechanical Engineering, 6+ years in complex hardware design, and strong CAD/GD&T skills, with a focus on manufacturability and high-quality integration.

Qualifications

• BS in Mechanical Engineering or related field.
• 6+ years of experience in mechanical design for complex hardware systems.
• Proficiency in CAD tools SolidWorks, Creo, NX and GD&T.
• Experience with precision assemblies involving optics, electronics, or thermal components.
• Strong understanding of materials, tolerances, and manufacturing processes (CNC, injection molding, sheet metal).
• Experience working with contract manufacturers (CMs) from prototype to production.
• Comfortable working cross-functionally and resolving ambiguous integration challenges.
• Hands-on mindset—willing to jump into builds, debug, and iterate quickly.

Responsibilities

• Own detailed mechanical design including 3D modeling, drawings, tolerancing, and documentation.
• Drive mechanical integration of electrical, optical, and thermal subsystems into cohesive product designs.
• Collaborate with EE, photonics, and systems teams to resolve cross-domain design challenges.
• Work hands-on with contract manufacturers to develop tooling, jigs, and fixtures for build and test.
• Validate manufacturability (DFM/DFA) and drive design improvements for yield, cost, and reliability.
• Support prototype builds, debug mechanical issues, and iterate quickly.
• Define assembly processes and ensure designs are production-ready.
• Manage ECOs, revisions, and release of mechanical documentation.

Skills

CAD tools

GD&T

Cross-functional collaboration

Hands-on assembly

Education

BS in Mechanical Engineering

Tools

SolidWorks

Creo

NX

Job description

Position:Sr. Staff Engineer, Mechanical Design

Location: San Jose, CA

Job Id:720

# of Openings:0

This job requires experience in optoelectronics and/or semiconductors.

Location: San Jose (on-site)

Ayar Labs is shattering AI data bottlenecks by moving data at the speed of light. As pioneers of co-packaged optics (CPO), we are using light instead of electricity to move data faster, further, and with a fraction of the energy needed to fuel the explosive growth of AI models.

Backed by industry giants like NVIDIA, Mediatek, AMD and Intel and manufactured in partnership with the world’s leading semiconductor ecosystem, Ayar Labs’ co-packaged optics solution is key to unleashing next-generation AI scale-up architectures.

We’re looking for a hands‑on Mechanical Engineer to own the physical realization of our products—from concept through production. This engineer will be responsible for turning complex electrical and photonics systems into robust, manufacturable hardware, working closely with cross‑functional teams and external partners.

This role is ideal for someone who thrives in fast‑paced environments, enjoys solving integration challenges, and likes seeing designs come to life on the factory floor.

Key Responsibilities

• Own detailed mechanical design including 3D modeling, drawings, tolerancing, and documentation
• Drive mechanical integration of electrical, optical, and thermal subsystems into cohesive product designs
• Collaborate closely with EE, photonics, and systems teams to resolve cross‑domain design challenges
• Work hands‑on with contract manufacturers (CMs) to develop tooling, jigs, and fixtures for build and test
• Validate manufacturability (DFM/DFA) and drive design improvements for yield, cost, and reliability
• Support prototype builds, debug mechanical issues, and iterate quickly
• Define assembly processes and ensure designs are production‑ready
• Manage ECOs, revisions, and release of mechanical documentation

Required Qualifications

• BS in Mechanical Engineering or related field
• 6+ years of experience in mechanical design for complex hardware systems
• Strong proficiency in CAD tools (e.g., SolidWorks, Creo, NX) and GD&T
• Experience with precision assemblies involving optics, electronics, or thermal components
• Solid understanding of materials, tolerances, and manufacturing processes (CNC, injection molding, sheet metal, etc.)
• Experience working with CMs and taking products from prototype to production
• Comfortable working cross‑functionally and resolving ambiguous integration challenges
• Hands‑on mindset—willing to jump into builds, debug, and iterate quickly

Preferred Qualifications

• Master's degree in Mechanical Engineering
• Experience with optical or photonics packaging
• Familiarity with thermal design and analysis
• Experience in high‑volume manufacturing environments
• Prior startup or fast‑paced product development experience

Salary range: $150,000 - $180,000

Ayar Labs is an Equal Opportunity Employer and is strongly committed to all policies which will afford equal opportunity employment to all qualified persons without regard to age, sex, national origin, race, color, ethnicity, creed, religion, gender identity, sexual orientation, disability, veteran status, or any other characteristic protected by law. It is the policy of Ayar Labs to provide reasonable accommodation when requested by a qualified applicant or employee with a disability, unless such accommodation would cause an undue hardship. Veterans are more than welcome and encouraged to apply.