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About the Role
We’re looking for a Staff Mechanical Engineer to own and architect critical mechanical systems across the Orion Sleep System. This role operates at a system level, driving architecture, design quality, manufacturability, and execution from early concept through mass production. You’ll work deeply across thermal systems, fluid routing, enclosures, CMF, mechanisms, and high-precision assemblies, while influencing engineering standards, design direction, and execution velocity. This is a hands-on technical leadership role embedded with Operations, Quality, EE, FW, Reliability, and our global manufacturing partners.
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
Requirements
- 8+ 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 → EVT → DVT → PVT → MP
- Hands-on engineering mindset—comfortable in labs, factories, and design reviews
- Strong technical communication and ability to influence across teams without direct authority
Skills
- CAD (SolidWorks or equivalent)
- DFM/DFA
- GD&T
- Thermoelectric (TEC/Peltier) systems
- Thermal-regulation platforms
- CMF
- Plastics
- Sheet metal
- Mechanisms
- Thermal systems
- High-volume manufacturing
Experience Level
- Staff Engineer
About the Company
- Orion is building the next generation of intelligent sleep technology—thermal regulation, advanced sensing, and beautifully engineered hardware designed to improve sleep quality and long-term health.
- We’re ramping toward mass production and scaling globally.
- Mechanical Engineering is core to how our system functions, feels, and performs night after night.