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About the Role

Merge is building the most advanced interface to the brain, capable of interacting with neurons at unprecedented scale and bandwidth. Delivering that capability in form factors that anyone would want to use will require engineering at the frontier of what’s possible. We’re assembling a team of exceptional builders across electrical engineering, mechanical engineering, mixed-signal IC design, materials science, systems engineering, and engineering physics. We reason from fundamentals, move comfortably across disciplines, and build technology that scales. We prototype, test, and iterate in tight loops at unreasonable speed because the platform we build makes the science possible.

Responsibilities

Drive the mechanical architecture and packaging of high-density PCBAs, sensors, mixed-signal components, cables/flexes, thermal interfaces, and user-facing structures, selecting materials and processes that balance performance, durability, manufacturability, and biocompatibility where relevant.
Execute tight iteration loops using 3D printing, CNC, sheet metal, soft goods, quick-turn tooling, and other rapid fabrication methods to validate form, fit, function, and key engineering risks quickly.
Own thermal modeling and validation of compact integrated electronic systems, ensuring high-performance ICs operate within strict temperature and form-factor constraints and driving cross-disciplinary thermal solutions across the system architecture.
Design scientist-facing instrumentation and mechanical tooling—fixtures, jigs, mounts, sample holders, alignment/calibration mechanisms, environmental interfaces, and test stands—that turn manual or expert-dependent setups into repeatable workflows.
Define quantitative performance and acceptance criteria for those setups, including tolerance, accuracy, repeatability, drift, calibration, environmental stability, and measurement uncertainty as appropriate; validate them with data and document procedures so another user can reproduce the result.
Own the transition from prototype to production through EVT/DVT/PVT or equivalent, applying DFM/DFA and working directly with vendors to develop tooling, establish inspection/acceptance criteria, and resolve yield or reliability issues.
Work intimately with Electrical Engineering, Software/Platform, Industrial Design, Clinical, and scientists to ensure physical systems meet device-performance, measurement-quality, usability, and experimental requirements.
Establish rigorous testing protocols for mechanical reliability and repeatability, including drop, ingress, fatigue, wear, thermal cycling, calibration drift, and other application-specific failure modes.

Requirements

Deep experience designing complex mechanical hardware and a track record of personally taking designs through build, test, failure analysis, and multiple product turns.
Strong fundamentals in tolerance analysis, materials/process selection, thermal design, mechanical architecture, and design verification.
Experience delivering manufacturable designs and working directly with vendors through tooling, production release, and yield/reliability issues.
A builder’s instinct for rapid prototyping: you know when a rough fixture is enough to learn, when precision matters, and how to instrument the result so the next decision is obvious.
A systems mindset toward experimental tooling: you care about datums, calibration, repeatability, error budgets, ergonomics, documentation, and whether the next scientist can reproduce the setup without you.
Empathy for scientists and other technical users; recurring support requests make you want to build a durable tool or platform rather than become the permanent human workaround.
A rigorous, analytical approach to problem-solving and a willingness to challenge assumptions in a fast-moving R&D environment.

Skills

3D printing
CNC
Sheet metal
Soft goods
Quick-turn tooling
Thermal modeling
Mechanical tooling
DFM/DFA
Mechanical reliability testing
Scientific instrumentation
Precision motion/alignment
Medical devices
Implantables
Lab automation
Lightweight test automation
Data analysis

Location

Remote

Work Type

Full-time

Experience Level

Mid-level
Senior

About the Company

Merge Labs is a frontier research lab with the mission of bridging biological and artificial intelligence to maximize human ability, agency and experience.
We’re pursuing this goal by developing fundamentally new approaches to brain-computer interfaces that interact with the brain at high bandwidth, integrate with advanced AI, and are ultimately safe and accessible for anyone to use.

Equal Opportunity

Merge Labs does not discriminate on the basis of race, color, religion, national origin, age, sex, sexual orientation, gender, gender identity, gender expression, marital status, physical or mental disability, medical condition, genetic information, family status, ancestry, citizenship, U.S. military (state and federal) and veteran status, or any other legally protected status.
It is our intention that all applicants be given equal opportunity and that selection decisions be based on job related factors.
We are an equal opportunity employer.
Pursuant to the San Francisco Fair Chance Ordinance, we will consider for employment qualified applicants with arrest and conviction records.
We are committed to providing reasonable accommodations to applicants with disabilities, and requests can be made by emailing accommodations@merge.io.