Staff Mechanical Engineer, Communications Hardware

Jobtailor; Arizona; On-site; USD 120,000 - 180,000; Full time

Job summary

Axon is seeking a senior mechanical design engineer to lead the development of rugged, portable devices from concept through high-volume production. You will drive electro-mechanical integration, balancing size, weight, durability, sealing, thermal and RF performance while ensuring manufacturability and cost targets.

You will lead a small team of mechanical engineers, partner with CAD, RF, and industrial design, and guide production ramp, EVT/DVT/PVT, and certification activities.

Qualifications

• 12+ years of mechanical product design experience, ideally with ruggedized, portable, wearable, or compact electronic products.
• Proven track record taking hardware from concept through EVT/DVT/PVT and high-volume manufacturing.
• 5+ years of technical leadership experience, including directing teams of 3+ mechanical engineers.
• Bachelor’s degree in Mechanical Engineering or equivalent.
• Deep experience with plastic injection molding, stamping, die-casting, machining, adhesives, and bonded components.

Responsibilities

• Own mechanical design from concept through high-volume production for ruggedized hardware.
• Develop designs balancing size, weight, durability, sealing, thermal performance, RF performance, manufacturability, and cost.
• Design complex components and assemblies using injection molding, stamped metal, die casting, machining, adhesives, and bonded joints.
• Build and analyze proof-of-concept prototypes and validate designs through FEA, tolerance analysis, and physical testing.
• Design for drop, shock, vibration, durability, and IP66/IP68 protection.
• Own electro-mechanical integration across PCB/PCBA, flex circuits, batteries, antennas, and internal components.
• Travel domestically and internationally as needed to support vendors and manufacturing partners.

Skills

Mechanical design

Technical leadership

Cross-functional communication

Prototyping

Education

Bachelor's degree in Mechanical Engineering or equivalent

Tools

Creo (3D CAD)

FEA

DFM/DFA

Injection molding

Die casting

PCB/PCBA integration

RF systems

Job description

• Own mechanical design from concept through high-volume production for compact, ruggedized, wireless-connected hardware


• Develop designs balancing size, weight, durability, sealing, thermal performance, RF performance, manufacturability, and cost


• Design complex components and assemblies using injection molding, stamped metal, die casting, machining, adhesives, and bonded joints


• Build and analyze proof-of-concept prototypes and validate designs through FEA, tolerance analysis, and physical testing


• Design for drop, shock, vibration, durability, and IP66/IP68 dust and water ingress protection


• Own electro-mechanical integration across PCB/PCBA, flex circuits, batteries, antennas, and internal components


• Develop passive thermal-management solutions for compact products


• Design belt-, holster-, and body-mounted form factors for carry, wear ergonomics, and one-handed operation


• Integrate antennas and wireless systems with RF and electrical engineering teams


• Develop structures compatible with RF performance and FCC/IC certification requirements


• Partner with Industrial Design to preserve aesthetics, ergonomics, and UX intent


• Translate product requirements into quantifiable engineering requirements and validation targets


• Develop and execute mechanical verification plans


• Perform tolerance analysis, FEA, and physical testing to identify and mitigate design risks


• Participate in cross-functional design reviews and communicate technical risks, tradeoffs, and recommendations


• Partner with consultants, vendors, manufacturers, and operations teams on DFM/DFA and production readiness


• Drive part and assembly tolerance management for high-volume manufacturing


• Support EVT, DVT, PVT, certification, manufacturing ramp, engineering builds, and product maturation


• Travel domestically and internationally as needed to support vendors, manufacturing partners, engineering builds, and production readiness


• Founding member of the Axon 911 hardware team, helping establish technical foundations and engineering standards for ruggedized wireless-connected public safety devices

Requirements

• 12+ years of mechanical product design experience, ideally with ruggedized, portable, wearable, or compact electronic products


• Proven track record taking hardware from concept through EVT/DVT/PVT and high-volume manufacturing


• 5+ years of technical leadership experience, including providing technical direction to teams of 3+ mechanical engineers


• Bachelor’s degree in Mechanical Engineering or equivalent experience


• Deep experience designing plastic injection-molded, stamped metal, die-cast, machined, adhesive, and bonded components and assemblies


• Strong proficiency in Creo or comparable 3D CAD software


• Strong expertise in DFM/DFA, tolerance analysis, FEA, prototyping, and physical validation


• Experience designing to MIL-STD-810 and IP66/IP68 ruggedization standards


• Experience designing compact products for carry and wear ergonomics, including belt-, holster-, or body-mounted form factors and one-handed operation


• Experience integrating PCB/PCBA, flex circuits, batteries, antennas, and other electro-mechanical components


• Experience designing wireless or connected hardware, including antenna integration, keep-out zones, RF-transparent materials, EMI/EMC shielding, and mechanical considerations for FCC/IC certification


• Experience developing passive thermal-management solutions and balancing battery, power, runtime, size, weight, and thermal constraints


• Ability to preserve Industrial Design and UX intent while balancing mechanical, electrical, RF, durability, manufacturing, and certification requirements


• Experience partnering with external consultants, vendors, and manufacturing partners through DFM/DFA, engineering builds, and production ramp


• Ability to translate product requirements into quantifiable engineering deliverables, resolve competing design constraints, and communicate technical decisions across cross-functional teams


• Flexibility to travel globally roughly once per month (15%+), alongside domestic trips when required


• Relocation candidates must be currently based in the U.S. and authorized to work for a U.S. employer

Core Competencies

Demonstrates extensive mechanical design expertise, particularly in ruggedized and compact electronic products, with a strong focus on integrating electro-mechanical components and ensuring compliance with industry standards. Proven ability to lead technical teams, manage product development from concept to high-volume manufacturing, and balance design requirements with manufacturing constraints.

Highest-signal resume keywords

• Mechanical Product Design


• Technical Leadership


• 3D CAD Software (Creo)


• DFM/DFA Expertise


• Ruggedization Standards (MIL-STD-810, IP66/IP68)

ATS Optimization Keywords

Hard Skills

• Mechanical Design


• Tolerance Analysis


• Finite Element Analysis (FEA)


• Prototyping


• Injection Molding


• Die Casting


• Machining


• Adhesive Bonding


• Electro-Mechanical Integration


• Thermal Management Solutions

Soft Skills

• Cross-Functional Communication


• Technical Direction


• Problem Solving


• Collaboration


• Flexibility

Industry Keywords

• Ruggedized Hardware


• Wireless-Connected Devices


• Product Verification Testing (EVT/DVT/PVT)


• Industrial Design


• User Experience (UX)

Tools & Technologies

• 3D CAD Software


• PCB/PCBA Integration


• RF Systems


• Manufacturing Readiness Tools


• Validation Testing Equipment