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Mechanical Engineer (NPI)

Hullbot - Sydney, NSW, Australia - In-office

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Hullbot is building autonomous underwater robots that inspect and clean ship hulls to reduce biofouling, fuel consumption, and emissions in the maritime industry. This is a Mechanical Engineer role focused on New Product Introduction (NPI)—the critical transition from prototype to production-ready systems. You will own design for manufacture and reliability on assigned mechatronic modules and subsystems. Your responsibilities include reworking parts and assemblies for producibility and consistent quality; collaborating with R&D early to shape designs for manufacturability rather than inheriting locked-in decisions; analyzing fleet reliability data and returned hardware to identify root causes of field failures; implementing design changes and rolling them into production; defining and proving controlled-environment processes (potting, sealing, bonding) with documented materials, cure schedules, and acceptance criteria; working with external suppliers and machine shops on design-for-manufacture reviews and first-article inspections; developing work instructions and process documentation; and driving continuous improvement in reliability, cycle time, cost, consistency, and first-pass yield as production volumes scale. You'll use 3D CAD, tolerance analysis, and production/field data to solve problems analytically. You'll be hands-on—in the workshop, on production lines, and pulling apart returned hardware to iterate on improvements. The role requires clear ownership, cross-team collaboration, and comfort in a fast-moving environment where documentation and knowledge-sharing between small teams is essential. The company operates an advanced manufacturing facility in Marrickville, Sydney, with flexible work arrangements available. Culture emphasizes visible, immediate impact and rapid learning. REQUIREMENTS: - Degree in Mechanical Engineering, Manufacturing Engineering, or equivalent hands-on experience - Strong 3D CAD skills (Onshape, SolidWorks, Fusion 360, NX, or similar) with focus on clean, scalable document structures - 3+ years in mechanical design, manufacturing, or NPI, including hands-on involvement taking products from prototype through repeatable production - Experience designing and optimizing parts for large-quantity production - Strong understanding of manufacturing processes, tolerances, and materials; confident with tolerance stack-ups and supplier-ready drawings - Analytical and data-focused approach: comfortable using test, production, and field failure data to find root causes - Experience designing jigs, fixtures, and production tooling - Experience with manual and automated production processes: injection molding, CNC machining, vacuum casting and forming, potting and encapsulation - Day-to-day experience with MRP/ERP systems: managing parts, BOMs, and supplier communication - Flexible, collaborative approach with clear ownership and cross-team comfort BONUS: - Production experience with underwater, harsh-environment systems, ingress protection, or corrosion resistance - Sealing and pressure-housing design: O-rings, glands, penetrators, corrosion and material compatibility - Robotics or electromechanical product manufacturing background

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