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Salary: USD 160,000 - 180,000 / annual
Lunar Energy is seeking a Staff Mechanical Engineer to lead the full product development lifecycle of mechanical systems for home energy products. This is a hands-on technical leadership role where you'll drive mechanical design, manufacturing support, and cross-functional collaboration for clean energy hardware.
Key Responsibilities:
- Own mechanical design from concept through high-volume production, including 3D modeling, detailed 2D drawings with GD&T, and design analysis (tolerance stackup, FEA, FMEA, root cause analysis)
- Design and develop test fixtures, jigs, and automated test equipment (ATE) for high-cycle-count applications, including PCBA bed-of-nails fixtures
- Conduct prototyping using 3D printing, machining, sheet metal, laser cutting, and general machine shop tools
- Manage bills of materials, cost and mass roll-ups, vendor relationships, and engineering releases
- Define manufacturing processes, inspection methods, and work instructions for electromechanical assemblies
- Support on-site build at domestic and international contract manufacturing sites (10–20% travel)
- Collaborate with electrical engineers, automated test engineers, and cross-functional teams to refine product designs for market impact, reliability, and manufacturability
- Conduct design reviews, generate technical documentation, and communicate complex engineering concepts clearly
Required Qualifications:
- Extensive experience with 3D modeling software (Onshape, NX, Solidworks)
- Deep knowledge of 2D drawing creation and GD&T
- Proficiency in design analysis: tolerance analysis/stackup, statics/load path analysis, finite element analysis (FEA), root cause analysis, and design FMEA
- Experience designing test fixtures, jigs, and mechanical components for high-cycle applications
- Knowledge of PCBA bed-of-nails fixture design and PCBA management (mechanical control outline generation)
- Familiarity with electronic test equipment and basic electromechanical troubleshooting
- Experience with fine-pitch assemblies, strain gauge measurements, and stress analysis on PCBAs
- Working knowledge of pneumatic cylinders, control methods, and thermal management techniques
- Prototyping skills across multiple manufacturing processes
- Experience communicating with component suppliers, design-for-manufacturing reviews, first article inspection, and part production approval processes
- Ability to generate detailed design documentation and work instructions
- Strong verbal and written communication skills; ability to drive projects cross-functionally and give/receive feedback
- Willingness to travel 10–20% for on-site manufacturing support
