Senior Mechanical Engineer

About Sandbar

Sandbar is an interface company in New York City. We aim to expand human thinking. Our team has built software, ML, hardware, and consumer products across Meta, CTRL-labs, Apple, Peloton, and Equinox.

Our first product is Stream, is private voice ring that extends your thinking. Stream has been featured in WSJ, Bloomberg, Wired, and Time's Best Inventions of the Year.

Join us in creating technology that extends human thinking.

About

We're looking for a Senior Mechanical Engineer to own the mechanical design of our wearable products.. You'll take parts and assemblies from concept through prototyping, EVT/DVT/PVT, and into mass production. You'll work closely with our Electrical, Firmware, Industrial Design, Quality, and Operations teams, as well as our contract manufacturers and suppliers.

This role is perfect for a hands-on engineer who has shipped high-volume consumer electronics, loves the challenge of packing a lot into a very small space, and wants real ownership at an early-stage company.

Responsibilities

• Define mechanical architecture of new products
• Own the mechanical design of key parts, subsystems, and full product assemblies, from concept through mass production
• Build and test prototypes fast; use the results to make clear design decisions
• Package electronics into a small wearable form factor, including PCBs, flexes, batteries, antennas, sensors, microphones, and haptics
• Design plastic, metal, and elastomer parts for high-volume manufacturing (e.g., injection molding, insert/overmolding, CNC, MIM, stamping)
• Release production-ready 3D CAD and 2D drawings with GD&T; run tolerance stack-ups
• Drive design for manufacturing and assembly (DFM/DFA) with contract manufacturers and part suppliers
• Plan and run mechanical validation and reliability testing (drop, tumble, ingress/water resistance, wear, fatigue, sweat/chemical exposure); lead root cause analysis
• Balance comfort, fit, durability, and cosmetics with Industrial Design for a product people wear all day
• Support engineering builds at our manufacturing partners, including on-site factory support
• Document designs and decisions clearly, and help shape how our hardware team works

Qualifications

• Bachelor's or Master's degree in Mechanical Engineering or a related field
• 7+ years of mechanical design experience in consumer electronics
• Shipped at least one high-volume consumer electronics product through EVT → DVT → PVT → MP
• Strong 3D CAD skills (e.g., OnShape, Creo, or SolidWorks) and 2D drawings with GD&T
• Hands-on experience with tolerance analysis, DFM/DFA, and plastic and metal part design
• Solid knowledge of materials and high-volume manufacturing processes
• Experience working directly with contract manufacturers and suppliers
• Clear written and verbal communication; comfortable in ambiguous, fast-moving environments
• Must have ability to travel internationally
• Nice to Have
• Experience shipping wearables (rings, watches, earbuds, fitness trackers, or similar)
• Experience with miniaturized assemblies, waterproofing, and small-battery or wireless-charging integration
• Experience designing for human factors, fit, and comfort across a range of body sizes
• Experience with highly cosmetic parts and surface finishes (e.g., PVD, anodizing, polishing, coatings)
• Experience at an early-stage startup
• FTE Benefits
• Health, vision, and dental benefits
• Company-sponsored 401(k)
• Unlimited PTO and sick time
• Early stage equity