The Mechanical Engineer is responsible for the mechanical and electro-mechanical design, development, and validation of Headset, Professional Audio and Critical Communications products from concept through production. This role delivers robust, cost-effective, and manufacturable solutions that meet performance, reliability, ergonomic, and regulatory requirements, while supporting customer satisfaction and business objectives.Key Responsibilities:Perform mechanical and electro-mechanical research, design, and development of Headset, Professional Audio and Critical Communications products to meet specifications, regulatory requirements, and customer expectations.Create assembly, customer, production, and detail mechanical drawings.Analyze, develop, verify, and implement product improvements and corrective actions to address quality or performance issues.Perform mechanical design, prototyping, verification, and documentation for new and existing products.Collaborate with Acoustic Engineering, Mechanical Engineering, Supply Chain, Product Management, Project Management, Manufacturing, and other engineering disciplines to define requirements, research solutions, and implement designs that meet customer and engineering specifications on time and within budget.Design and develop headset assembly components (headbands, yokes, hinges, ear-cup housings, sliders, boom arms), speaker cabinets, speaker horns, mounting grids, and related accessories, as well as rackmounted, portable, and desktop electronic enclosuresDevelop and maintain product cost models and monitor product costs throughout the product lifecycle.Contribute to design risk analysis by applying structured risk management tools such as Failure Mode and Effects Analysis (FMEA) and Focus Area Matrix methodologies.Perform interference and tolerance stack-up analysis for electro-mechanical assemblies.Conduct structural, thermal, and fluid dynamics simulations to optimize designs for stress, deformation, stability, airflow, and thermal dissipation.Define mechanical constraints and board outlines for printed circuit board assemblies, review PCB layouts for electro-mechanical fit and interference.Develop and maintain mechanical and top-level bills of material (BOMs) and assembly drawings.Support and participate in regulatory certification and manufacturer specific approval efforts, including preparation of the technical documentation required for Federal Aviation Administration (FAA) compliance.Initiate Engineering Change Orders (ECs) to update 3D models and technical documentation.Advise manufacturing to update existing product to meet current manufacturing techniques.Perform other duties as assigned.
