Sr. Mechanical Engineer - Sensor Products & Systems

About UltraSense Systems

UltraSense Systems, headquartered in Silicon Valley, is revolutionizing human-machine interfaces (HMI) through its cutting-edge SmartSurface technology. Our InPlane Sensing platform seamlessly integrates touch, lighting, and haptic feedback into everyday surfaces, delivering intuitive, responsive, and premium user experiences across automotive, consumer electronics, and other industries.

Learn more: www.ultrasensesys.com

Job Title

Sr. Mechanical Engineer - Sensor Products & Systems

Summary

We are seeking a skilled Mechanical Engineer to lead the design and characterization of mechanical systems and sensors for mass-produced consumer electronics and automotive modules. The ideal candidate will bring strong hands-on experience in product mechanical design, DFM/DFA optimization, material selection, and tolerance analysis to ensure robust, manufacturable, and reliable solutions.

Major Responsibilities

Mechanical Design

·       Develop plastic and metal parts and assemblies using CAD tools such as ProE or Creo.

·       Optimize designs for high-volume manufacturing through DFM/DFA and cost-efficiency tradeoff analysis.

·       Work with OEM partners to support NPI programs through mass production.

System & Sensor Characterization

·       Characterize mechanical systems and sensor performance for modules incorporating capacitive, force, and ultrasonic sensing, as well as LED backlighting and haptic feedback.

·       Validate designs through prototyping, test planning, and performance evaluation.

Tolerance & Quality Assurance

·       Perform statistical tolerance stack-up analysis and apply GD&T to ensure robust assemblies.

·       Ensure designs meet reliability, ingress protection, and applicable automotive requirements.

Cross-functional Collaboration

·       Work closely with EE, NPI, and manufacturing teams to ensure seamless product integration.

·       Support failure analysis and root-cause correction during development and mass production.

·       Manage cross-time-zone communication and collaborate effectively with global customers and internal teams.

Minimum Qualifications

·       Bachelor's or Master's degree in Mechanical Engineering or a related field.

·       5+ years of experience in mechanical design for mass-produced consumer electronics or automotive modules.

·       Strong understanding of DFM/DFA, tolerance analysis, and GD&T.

·       Experience with mechanical characterization, prototyping, and validation testing.

·       Fluent English and Mandarin communication skills, both written and spoken.

Preferred Qualifications

·       Experience with FPC design, automotive connectors, or flexible interconnects.

·       Knowledge of reliability test standards and environmental sealing for dust and liquid ingress protection.

·       Familiarity with automotive quality systems and protocols such as IATF 16949.