Senior Mechanical Design Engineer

The Role

LettrLabs is reinventing direct mail. With our own in-house handwriting robotics, we’re challenging traditional direct mail manufacturing from the ground up. We’re looking for a Senior Mechanical Design Engineer to own the mechanical design and development of complex electromechanical systems from concept through production — and to be instrumental in building our next-generation production automation platform.

You’ll take projects end-to-end: translating requirements into robust, manufacturable designs, validating them through analysis and prototyping, and seeing them through to commissioning. You’ll work closely with cross-functional partners in electrical, controls, manufacturing, and quality, as well as external vendors and suppliers. This is a hands-on, high-ownership position for an engineer who is equally comfortable at a whiteboard, in CAD, and on the shop floor.

Why Join Us

• Design the machines that make our product possible — you’re not supporting a production line, you’re building it
• High ownership from day one: end-to-end accountability for complete mechanical systems, not isolated components
• Work alongside a team of engineers who bring the same grit and ownership mindset to every problem
• Real exposure to leadership and cross-functional partners — your design decisions are visible and matter
• A culture of grit, perseverance, and performance that values engineers who get energized by hard problems
• Competitive compensation, growing benefits, and a culture that rewards initiative.

What You Will Own

• Own entire mechanical systems and sub-systems across the full product lifecycle — requirements generation, concept development, detailed design, analysis, prototyping, validation, and commissioning
• Design precision motion systems incorporating belts, pulleys, gears, bearings, shafts, and related drivetrain components
• Develop sheet metal components and assemblies with a strong understanding of manufacturing processes and tolerances
• Apply DFM/DFA principles to drive cost, quality, and reliability across every design decision
• Perform engineering analysis using hand calculations and FEA to size components, validate designs, and de-risk failure modes
• Select appropriate materials and finishes based on structural, thermal, environmental, and cost requirements
• Build and test prototypes rapidly to validate concepts and iterate quickly toward production-ready designs
• Create and maintain detailed engineering drawings, GD&T, BOMs, and design documentation
• Mentor junior engineers and contribute to design reviews and best practices

What Success Looks Like

• Mechanical systems delivered on time from requirements through commissioning with minimal rework
• Designs that pass validation the first time — rigorous analysis and prototyping reduce costly late-stage surprises
• Cross-functional partners describe you as someone who makes integration easier, not harder
• Junior engineers improve measurably through your mentorship and design review participation

What You Bring

• 5+ years of experience in mechanical design and product development
• Deep, hands-on experience with motion systems and their core components — belts, pulleys, gears, bearings, and shafts
• Working expertise in sheet metal design and the associated manufacturing methods (bending, CNC machining, laser cutting, waterjet, additive manufacturing)
• Strong command of Design for Manufacturing and Design for Assembly (DFM/DFA)
• Strong fundamentals in mechanical engineering — statics, dynamics, mechanics of materials, tolerancing
• Proven experience with FEA and hand calculations to drive and validate design decisions
• A track record of owning complete mechanical systems and sub-systems from requirements through commissioning
• Experience working directly with vendors and suppliers throughout design and manufacturing
• Bachelor’s degree in Mechanical Engineering or a related field

Nice to Haves

• Master’s degree in Mechanical Engineering or a related discipline
• Experience in robotics, automation, or industrial machinery
• Proficiency with SolidWorks, NX, or similar CAD platforms and PDM/PLM systems
• Familiarity with GD&T (ASME Y14.5) and tolerance stack-up analysis