Mechanical Design Engineer for Athletic System

About the project

Senior Mechanical Design Engineer Complete Machine Design | Prototype Development | Long-Term Opportunity Engineering First. CAD Second. THE LAB Athletic Systems is developing an innovative athletic resistance training system and is seeking an experienced Senior Mechanical Design Engineer to transform an existing engineering architecture into a complete prototype-ready CAD package. This is NOT a concept design project. The product architecture has already been developed through extensive engineering, trade studies, component selection, manufacturing analysis, human factors research, and prototype planning. We are NOT looking for someone to redesign the machine. We are looking for an engineer who can transform an existing engineering architecture into a complete, manufacturable mechanical design suitable for prototype fabrication and future production. If your primary skill is CAD drafting, this project is probably not a good fit. If your strength is solving engineering problems and creating production-ready mechanical designs, we would like to hear from you. Project Scope Develop a complete engineering CAD package including: Complete 3D machine assembly Individual manufactured components Weldments Sheet metal components Machined parts Bearings Shafts Cable routing Linear motion assemblies Height adjustment mechanism Engine module packaging Electronics packaging Structural frame Assembly drawings Exploded assemblies Manufacturing drawings Bill of Materials (BOM) STEP files Revision-controlled CAD package suitable for prototype fabrication Required Experience Please apply only if you have experience designing complete mechanical products or machinery. Examples include: Industrial machinery Robotics Automation equipment Medical devices Manufacturing equipment Fitness equipment Special-purpose machinery Electromechanical systems Experience with: Design for Manufacturing (DFM) Design for Assembly (DFA) Prototype fabrication Mechanical packaging Manufacturing documentation is required. Preferred CAD Platforms SolidWorks Autodesk Inventor Equivalent professional CAD platforms will also be considered. This Project Is NOT CAD drafting only Reverse engineering Product styling Industrial design only Rendering only Student projects We are looking for engineering judgment and real-world mechanical product development experience. Required Screening Questions Please answer every question. Generic proposals will not be considered. Engineering Experience Describe the most technically challenging mechanical or electromechanical product that you personally helped design. What percentage of the engineering and CAD work was your responsibility? Did the product reach prototype, production, or commercialization? Describe one engineering decision that significantly improved manufacturability. Describe one design issue discovered during prototype fabrication and how it was resolved. Manufacturing Experience Have you produced complete fabrication drawing packages that were successfully built? Have you worked directly with fabrication shops, machine shops, or contract manufacturers? Which manufacturing processes have you designed for? CNC machining Sheet metal Weldments Injection molding Castings Extrusions Composite fabrication Additive manufacturing Mechanical Design Describe your experience designing systems containing: Electric motors Bearings Shafts Cable systems Pulleys Linear guides Gearboxes Structural frames What CAD platform do you use professionally? How many years have you used it professionally? Engineering Judgment If another engineer owns the product architecture, what is your process for validating it before beginning detailed CAD? How do you balance performance, manufacturability, cost, and serviceability? Describe your approach to tolerance stack-up and assembly validation. What additional information would you require before preparing an accurate proposal? Project Planning Approximately how many engineering hours do you believe a project of this complexity would require? What assumptions are you making when preparing that estimate? What do you believe is the greatest technical risk in converting an existing engineering architecture into a prototype-ready CAD package? Portfolio Please include: Three complete mechanical assemblies that you personally designed. One fabrication drawing package. One exploded assembly. One example of a product that was actually manufactured. One project you are most proud of and explain why. IMPORTANT To confirm that you have read the complete project description, begin your proposal with the words: ENGINEERING FIRST Proposals that do not include these words or fail to answer the screening questions will not be reviewed. Selection Process We are looking for a long-term engineering partner, not simply someone to produce CAD. Shortlisted candidates will be invited to review a portion of the engineering package and participate in a technical discussion covering: How they would approach the CAD development. Questions they would ask before beginning. Manufacturing concerns they immediately identify. Their proposed development strategy. Estimated engineering effort. Areas of technical risk. Opportunities to improve manufacturability and serviceability without changing the underlying architecture. This discussion is intended to evaluate engineering judgment, communication, and problem-solving ability. Long-Term Opportunity The selected engineer may continue supporting: Alpha prototype revisions Beta development Manufacturing optimization Cost reduction Production CAD Future product family development

Skills required