Senior Mechanical Engineer (Continuous Improvement)

At WHOOP, we're on a mission to unlock human performance and healthspan. WHOOP empowers users to perform at a higher level through a deeper understanding of their bodies and daily lives.

WHOOP is looking for a Senior Mechanical Engineer to lead and drive critical design improvements, validation strategy, and sustaining engineering efforts for our flagship wearable products at scale. You are a proactive, highly organized engineer with strong problem-solving skills and a sharp eye for detail. You thrive in a fast-paced, execution-driven environment and can drive creative mechanical solutions with independence and sound technical judgement. You will mentor junior engineers and collaborate cross-functionally with Electrical Engineering, Manufacturing, Supply Chain, Quality, and Program Management to deliver high-impact product improvements driven by customer feedback and evolving business needs. You will work closely with global suppliers and contract manufacturers to execute validation builds and drive and scale design changes in production environments, with a focus on high-quality deliverables, robust risk management, clear technical communication, and manufacturing stability. WHOOP operates with urgency because our mission demands it. We build products for people who push their limits—and we hold ourselves to the same standard. If you’re energized by complex challenges, cross-functional collaboration, and the opportunity to improve hardware products at scale, this role will push you—and reward you.

Complete technical ownership of mechanical subsystems and components for current generation WHOOP hardware products, driving improvements from concept through implementation in mass production

Lead design, analysis, and development of mechanical solutions to improve product performance, reliability, manufacturability, and cost within existing production and design constraints

Lead engineering change implementation with vendors and contract manufacturers, ensuring clear communication and seamless integration into production

Define and lead DOE and validation strategies to optimize product and manufacturing performance

Lead root cause investigations and drive resolution of quality, yield, and reliability issues in production

Own and maintain CAD models and technical documentation (3D, 2D, BOMs, ECOs) to support design changes, validation, and high-volume manufacturing

Mentor junior engineers and promote strong engineering best practices

Travel internationally up to 20% to support manufacturing partners and production builds

BS or MS in Mechanical Engineering or a related field

5+ years of experience in the design, improvement, and sustaining of complex mechanical products, preferably in consumer electronics, wearables, or medical devices

4+ years of SolidWorks CAD experience with best practices in part design, tolerance analysis, advanced assemblies, configuration management, and integration of DFx/DfM feedback

3+ years of experience working with Tier 1 and 2 contract manufacturers, including driving engineering changes and sustaining production in Asia and North America

Demonstrated experience with high-volume manufacturing processes (e.g., injection molding, die casting, automated assembly), with a focus on yield, reliability, and cost optimization

Strong experience in root cause analysis, failure investigation, and implementing design or process improvements in production environments

Hands-on experience with prototyping and validation to support design changes and production improvements, along with experience in second sourcing, supplier qualification

Experience leading cross-functional efforts and mentoring junior engineers

Preferred experience with electromechanical systems, including integration of mechanical components with sensors, PCBs, and flex circuits in compact, high-volume products

Experience developing and scaling automated test systems, complex fixtures, or production validation infrastructure preferred

Preferred experience in wearable, health-focused, or other highly constrained consumer electronic products

Experience leading engineering efforts in fast-paced or startup environments with high ownership and cross-functional influence

Passion for health, human performance, and designing human-centered hardware preferred