Staff Mechanical Engineer, Communications Hardware (Hybrid)

Axon; Boston (MA); Hybrid; USD 109,000 - 190,000; Full time

Benefits offered by this job

Competitive salary and 401k

Discretionary PTO

Parental leave

Medical, dental, vision

Stock options

Job summary

Axon in Boston is seeking a Staff Mechanical Engineer for Communications Hardware to own mechanical design from concept through high-volume production. You will collaborate with ID, EE, RF, and manufacturing teams to build rugged, wireless devices used by public safety professionals.

We require 12+ years of mechanical design experience, 5+ years of technical leadership, and a strong background in plastic injection molding, DFM/DFA, FEA, and EMI/EMC considerations.

Qualifications

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

Responsibilities

• Own mechanical design from concept through high-volume production for compact, ruggedized, wireless-connected hardware.
• Develop mechanical designs that balance product requirements across size, weight, durability, sealing, thermal performance, RF performance, manufacturability, and cost.
• Design complex mechanical components and assemblies using plastic injection molding, stamped metal, die casting, machining, adhesives, and bonded joints.
• Build and analyze high-fidelity proof-of-concept prototypes and validate designs through FEA, tolerance analysis, and physical testing.
• Design for demanding field environments, including drop, shock, vibration, long-term durability, and IP66/IP68 dust and water ingress protection.
• Own electro‑mechanical integration across PCB/PCBA, flex circuits, batteries, antennas, and other internal components.
• Develop passive thermal‑management solutions to dissipate heat from electronics while maintaining compact product form factors.
• Design for carry and wear ergonomics, including belt-, holster-, and body‑mounted form factors and one‑handed operation.
• Partner with RF and electrical engineers to integrate antennas and wireless systems, including antenna placement, keep‑out zones, RF‑transparent material selection, and EMI/EMC shielding.
• Develop mechanical structures compatible with RF performance and FCC/IC certification requirements.
• Partner closely with Industrial Design to preserve product aesthetics, ergonomics, and UX intent without compromising durability, sealing, thermal performance, RF performance, or manufacturability.
• Translate product requirements into clear, quantifiable mechanical engineering requirements and validation targets.
• Develop and execute mechanical verification plans across environmental, structural, thermal, ingress, and durability requirements.
• Perform tolerance analysis, FEA, and physical testing to identify design risks and drive mitigation before production.
• Participate in cross‑functional design reviews and clearly communicate technical risks, tradeoffs, and recommendations.

Skills

Mechanical design

Ruggedization

DFM/DFA

FEA

Thermal management

Antenna integration

Cross-functional

Leadership

Education

Bachelor’s in Mechanical Engineering

Tools

Creo

Job description

Axon in Boston is seeking a Staff Mechanical Engineer for Communications Hardware to own mechanical design from concept through high-volume production. You will collaborate with ID, EE, RF, and manufacturing teams to build rugged, wireless devices used by public safety professionals.

We require 12+ years of mechanical design experience, 5+ years of technical leadership, and a strong background in plastic injection molding, DFM/DFA, FEA, and EMI/EMC considerations.