Mechanical Engineer

Merge Labs is a frontier research lab with the mission of bridging biological and artificial intelligence to maximize human ability, agency and experience. We’re pursuing this goal by developing fundamentally new approaches to brain-computer interfaces that interact with the brain at high bandwidth, integrate with advanced AI, and are ultimately safe and accessible for anyone to use.

About the Team

Merge is building the most advanced interface to the brain, capable of interacting with neurons at unprecedented scale and bandwidth. Delivering that capability in form factors that anyone would want to use will require engineering at the frontier of what’s possible. We’re assembling a team of exceptional builders across electrical engineering, mechanical engineering, mixed-signal IC design, materials science, systems engineering, and engineering physics. We reason from fundamentals, move comfortably across disciplines, and build technology that scales. We prototype, test, and iterate in tight loops at unreasonable speed because the platform we build makes the science possible.

About the Role

We are seeking a Mechanical Engineer to own the physical architecture and packaging of our BCI systems, spanning early-stage R&D prototypes to high-volume wearable products. You will act as the bridge between electrical performance and physical constraints, ensuring our devices are not only performant but also comfortable and durable. This role demands deep technical expertise in all aspects of the design and execution of deeply integrated systems containing high-performance electronics and the ability to drive designs from a "napkin sketch" to a manufacturable reality. You will own the full mechanical lifecycle, managing critical vendor relationships for fabrication and tooling, and setting the standard for mechanical engineering excellence at Merge Labs.

In this role, you will:

• Drive the mechanical packaging of high-density PCBAs, sensors, and mixed-signal components, selecting advanced materials that balance fabrication trends, durability, and biocompatibility.

• Execute tight iteration loops using rapid prototyping techniques (3D printing, CNC, soft goods) to validate form, fit, and function at "unreasonable speeds."

• Own the thermal modeling and simulation (CFD/FEA) of compact, integrated electronic systems, ensuring high-performance ICs operate efficiently within strict skin-temperature and form-factor constraints. Own and drive effective solutions for thermal management, crossing multiple disciplines across the entire system architecture.

• Own the transition from prototype to production (EVT/DVT/PVT). You will design for manufacturability (DFM) and assembly (DFA), working directly with vendors to develop tooling and resolve yield issues on the line.

• Work intimately with Electrical Engineering, Industrial Design, and Clinical teams to ensure the physical device meets all performance and user-experience requirements.

• Establish rigorous testing protocols for mechanical reliability (drop, ingress, thermal cycling) and, where applicable, ensure compliance with medical product requirements.

You might thrive in this role if you have:

• A Bachelor’s degree or greater in Mechanical Engineering and 5+ years of experience in hardware product design.

• Experience delivering multiple product turns, taking designs from initial concept through to successful mass production.

• Deep familiarity with thermal simulation tools (e.g., Ansys, FloTHERM) and practical heat dissipation strategies for handheld or wearable electronics.

• Extensive knowledge of modern fabrication trends, materials science, and molding processes (injection molding, machining, flexible circuits).

• Familiarity with medical product standards (ISO 13485, IEC 60601) is highly desirable; experience with implantable devices is a strong plus.

• A rigorous, analytical approach to problem-solving and a willingness to challenge assumptions in a fast-paced, R&D-heavy environment.

If you're excited about this role but don't meet every qualification, please apply. As we build, we're hiring for complementary strengths to form a high-impact team.

Merge Labs does not discriminate on the basis of race, color, religion, national origin, age, sex, sexual orientation, gender, gender identity, gender expression, marital status, physical or mental disability, medical condition, genetic information, family status, ancestry, citizenship, U.S. military (state and federal) and veteran status, or any other legally protected status. It is our intention that all applicants be given equal opportunity and that selection decisions are based on job related factors. We are an equal opportunity employer.

Pursuant to the San Francisco Fair Chance Ordinance, we will consider for employment qualified applicants with arrest and conviction records.

We are committed to providing reasonable accommodations to applicants with disabilities, and requests can be made by emailing accommodations@merge.io.