Sr Mechanical Engineer

Sr Mechanical Engineer I Direct Hire Onsite Minneapolis, MN Job Details Description Do you have experience working with complex plastic parts in a product development design arena? The Sr. Mechanical Engineer role is a critical leadership position focused on driving the design and development of innovative, high-performance hearing aids and related devices. Working with minimal supervision, this engineer will lead cross-functional teams in creating industry-leading product designs that meet stringent performance, quality, manufacturability, and cost requirements. This position not only involves technical execution and project leadership but also emphasizes mentoring others and contributing to continuous improvement efforts across the organization. JOB SUMMARY DESCRIPTION Under minimal supervision, this position is responsible for leading the design of new products and ensuring that they meet performance, quality, manufacturing, and cost requirements for standard and/or custom products. Must possess the communication ability, technical expertise, creativity, and internal drive to lead the creation of designs that are recognized as best- in-class in the hearing aid industry. Must be able to work well in a team environment and have a passion for continuous improvement. JOB RESPONSIBILITIES Generate system and component performance requirements. Lead the project team to document specific performance targets using historical data and high-level user requirements as a guide. Design new and innovative standard and custom hearing aids and other auxiliary devices which meet product requirements. Integrate new technologies into product designs. Propose design options that are manufacturable and harmonious with Industrial Design. Specify materials and finishes that are appropriate to meet all design requirements. Interface with internal and external suppliers to develop and implement new processes and technologies. Work with a cross-functional team to ensure that all manufacturing and performance requirements are met. Analyze component and assembly costs to ensure the designs meet product requirements. Ensure design verification and validation testing is completed and ensure that all criteria are met. Specify and perform design verification testing to ensure the designs meet product requirements. Support the design validation testing for all new parts and assemblies. Aid prototype and production debugging efforts to ensure that design intent is met, and parts are acceptable for form, fit and function. Ensure product quality by evaluating and dispositioning First Article Inspection data. Develop the technical project plan and manage work efforts to ensure project schedules are met and areas of high risk are identified and mitigated with appropriate risk mitigation plans. Lead design reviews. Generate mechanical design tasks and provide input into project timelines and schedules. Provide project status updates at team meetings as required. Collaborate with other cross-functional team members to create and maintain DFMEA documentation which ensures that all key areas of potential failure have been considered and addressed. Ensure the generation of accurate design documentation. Ensure the creation of accurate CAD models and drawings which communicate the design intent and ensure a high standard of quality. Ensure the creation of accurate and up-to-date online documentation using Starkey documentation procedures. Insure the creation of Engineering Change Orders (ECO) for release. Perform other duties commensurate with a "senior" engineer role. Mentor, train, and provide work direction to other engineers and designers. JOB REQUIREMENTS Education Bachelor's degree in mechanical engineering or related field with 7 years' experience Master of Science in Mechanical Engineering with 5 years' experience PhD Mechanical Engineering with 2 years' experience Experience Product Development environment required; hearing or medical device industry experience preferred. Knowledge / Technical Requirements Proficiency in ProE preferred. Advanced knowledge of injection molding processing and tooling required. Advanced knowledge of materials and processes used to manufacture injection molded plastic, stamped metal, and elastomeric components required. Advanced knowledge of product development best practices (i.e. DFM, DOE, DFMEA, Lean PD, etc....) required. Intermediate knowledge of geometric dimensioning and tolerancing required. Intermediate understanding of acoustics and vibration is highly desirable. Intermediate understanding and experience with various pieces of test equipment required. Proven ability to perform complex engineering analysis and calculations required. Competencies, Skills & Abilities Proven ability to work well in a team environment required. Ability to work with minimal guidance to make decisions and report progress required. Requires personal communication and conduct skills at a professional level. Excellent verbal and written communication skills required. Must be a self-starter with high initiative. Demonstrated leadership role in projects including ability to provide guidance and direction on the project to less experienced technical personnel required. Ability to keep current with new technologies and industry trends required. Salary and Other Compensation: The target pay rate for this position is between $105,000 - $135,000 annually. #LI-KS1

Created: 2026-03-04