Mechanical Design Engineer

About Level Zero

Level Zero is pioneering next-generation biosensor technology for precise, real-time monitoring of critical endocrine biomarkers. Recognised as one of the top 20 startups across all categories worldwide at TechCrunch Disrupt 2024 - and backed by top-tier organisations like SOSV and Entrepreneur First - we're pushing the boundaries of biochemistry and nanotechnology to revolutionize personalised health.

Founded by two seasoned engineers, we bring extensive experience in R&D, technical innovation, and commercial strategy to transform the way people monitor their health. Our mission is bold: to revolutionise health management by delivering clinical-grade data directly to individuals, wherever they are.

We're seeking driven innovators to join us in pushing the boundaries of biosensing and health tech, making personalised health monitoring a reality for everyone. To achieve this ambitious vision, we're assembling the best team in the world - dedicated to turning cutting-edge science into life-changing, real-world solutions.

We're looking for a Mechanical Design Engineer to help design, prototype and industrialise the mechanical and plastics architecture of Level Zero's wearable medical devices. Working closely with the founding team and multidisciplinary engineers, you'll take concepts from CAD-driven design through DFM/DFA, tooling and verification, building miniaturised components and assemblies that are reliable, comfortable to wear and manufacturable at scale. This is a hands-on role at the intersection of precision mechanical design, injection moulding, miniaturisation and medical product development.

What you'll do

• Own the mechanical design and development of plastic and mechanical components for wearable medical devices, including enclosures, skin-interface parts, internal mechanisms and sealed or fluid-handling subsystems.
• Design compact, highly integrated assemblies, working with electronics and sensing teams to fit complex functionality into small, body-worn form factors.
• Produce high-quality 3D CAD models, assemblies and engineering drawings to manufacturing standards.
• Perform tolerance analysis and tolerance stack-ups to ensure robust product performance and manufacturability.
• Create detailed design specifications, engineering requirements and mechanical architecture documentation.
• Develop, refine and execute verification test methods to evaluate product performance and reliability. Plan and conduct engineering testing, analyse results and iterate designs based on data.
• Lead mechanical investigations, identify root causes of failures and implement effective design improvements.
• Apply human-centred design practices by conducting human factors studies, usability evaluations and user research sessions, translating findings into actionable product and design improvements, particularly around wearability and comfort.
• Work closely with external suppliers and manufacturing partners to develop production-ready components.
• Specify and qualify bought-in components and work with suppliers to integrate them into the product.
• Collaborate closely with electronics, systems, quality, manufacturing and industrial design teams.
• Balance technical performance, usability, reliability, manufacturability and cost throughout the design process.
• Contribute to early-stage R&D, collaborating with engineering leadership to define and refine future design iterations.

What You Bring

The ideal candidate must have:

Master's degree with 2 - 4 years of industry experience in mechanical engineering, biomedical engineering or a related discipline.

Experience developing medical devices, wearables or other compact consumer or electromechanical products.

Experience designing products with user needs at the centre of development.

Experience designing miniaturised or highly integrated mechanical assemblies.

Experience designing sealed or leak-tight assemblies and developing associated test methods.

Excellent CAD and drafting skills including complex assemblies and surfacing where appropriate, with a strong understanding of engineering drawings, GD&T and manufacturing tolerances.

Experience performing tolerance stack analysis and applying statistical tolerancing where appropriate.

Experience creating engineering documentation including design specifications and product requirements.

Experience applying DFM, DFA and DFMA principles.

Experience working with external suppliers, manufacturers and tooling vendors.

Experience creating and refining mechanical test methods and verification plans.

Experience with DFMEA, PFMEA and structured engineering risk management.

Strong experience designing injection moulded plastic components for volume manufacture. Experience attending tooling trials, evaluating moulded parts and resolving manufacturing issues.

Proven ability to troubleshoot mechanical failures using structured root cause analysis.

Understanding of assembly methods including snap fits, heat staking, ultrasonic welding, adhesives or overmoulding.

Experience with engineering change control, product release processes and PLM systems.

Strong communication skills and ability to work within multidisciplinary engineering teams.

Comfortable taking ownership of significant subsystems while working with appropriate technical guidance.

Nice to have:

Experience designing skin-adhered or continuously worn medical devices

Experience designing pumps, valves, diaphragms, microfluidics or other fluid-handling mechanisms

Knowledge of ISO 13485, ISO 14971 or equivalent quality systems

Experience with verification and validation (V&V) testing

Experience with reliability, environmental, fatigue or life-cycle testing

Experience designing precision mechanical mechanisms

Experience with rapid prototyping, machining and 3D printing

Familiarity with Design of Experiments (DOE) and statistical data analysis

Experience supporting pilot builds, manufacturing scale-up and production transfer

Basic FEA experience for structural or thermal assessment

Prior work in a start-up or small company environment

Prior work in medical device development

Who You Are

We value culture as much as we value technical expertise, creating an environment that's equal parts collaboration, curiosity, and fun.

We're a fast-paced, mission-driven young team on a quest to make a lasting impact, fueled by uncompromising integrity, unwavering support for one another, and the thrill of exploring uncharted territories. Our passion for excellence drives everything we do, and we welcome individuals who share our commitment to shaping the future.

If our vision excites you, here are the qualities we look for:

You live and breathe integrity, tackling challenges with honesty and transparency.

You're a self-starter who loves diving into the unknown, collaborating on complex problems, and taking full ownership of results.

You excel at open, clear communication and see every piece of feedback as a springboard for growth—especially in a science and data-focused environment.

You're motivated by creating real impact, particularly when it comes to advancing human health.

You strike a balance between independence and collaboration, knowing when to seek support or invite others to join in.

You're confident in defending your ideas, while also valuing respectful, constructive debate as a path to better solutions.

You thrive in the dynamic atmosphere of a startup, constantly evolving your skill set and fearlessly applying what you learn.

What we offer

A full-time role with a competitive salary and equity options, reflecting our value in your expertise and potential.
An environment where you'll collaborate directly with the founding team at a leading biosensor startup, gaining access to industry experts and thought leaders.
The chance to grow with us, including ample opportunities for leadership, career advancement, and exploration.
Travel to New York and other potential sites for R&D purposes.
The excitement of working on cutting-edge technology, shaping strategic decisions, and driving innovation at an early-stage venture alongside a superstar team.