Senior Manufacturing Engineer (NPI)

At WHOOP, we're on a mission to unlock human performance. WHOOP empowers users to perform at a higher level through a deeper understanding of their bodies and daily lives. As a Senior Manufacturing Engineer, you will be responsible for developing manufacturing solutions that enable new products from early design through production ramp. You will work closely with Product Design, Mechanical, Electrical, Quality, and factory engineering teams to influence product design, define assembly strategies, and develop the fixtures, tooling, equipment, and processes required to manufacture products at scale. You will apply strong mechanical design fundamentals, DFX expertise, and hands-on manufacturing experience to identify manufacturing risks early, translate product requirements into robust manufacturing solutions, and solve complex technical challenges with a high degree of independence. RESPONSIBILITIES: - Partner closely with Product Design and Mechanical Engineering throughout product development to drive DFM, DFA, and DFX, identifying manufacturing risks and influencing product designs for assembly, quality, scalability, automation, and cost. - Develop manufacturing concepts and assembly strategies from early prototypes through production, translating product requirements into practical manufacturing processes, tooling, and equipment. - Design and develop fixtures, tooling, nests, gauges, and manufacturing aids used for assembly, alignment, bonding, welding, inspection, and test. - Own fixture and tooling development from concept through detailed design, tolerance analysis, fabrication, debugging, qualification, and release to production. - Apply GD&T, tolerance analysis, datum strategies, and mechanical design principles to ensure product and fixture designs support repeatable manufacturing and measurement. - Work with product engineering teams to evaluate component interfaces, assembly sequences, joining methods, tolerance stack-ups, and other design characteristics that impact manufacturability. - Develop and qualify manufacturing processes including adhesive bonding, heat staking, mechanical assembly, and other processes used in small consumer electronic devices. - Define critical process parameters, process windows, acceptance criteria, and controls to ensure manufacturing processes consistently meet product requirements. - Evaluate manual and automated assembly approaches and develop fixture and equipment concepts that enable appropriate levels of automation. - Use DOEs, process characterization, capability analysis, and failure analysis to validate manufacturing designs and optimize process performance. - Troubleshoot complex product, fixture, and process interactions during development builds and production ramp, driving issues to root cause and implementing robust engineering solutions. - Collaborate directly with contract manufacturers, equipment vendors, and tooling suppliers to develop, review, debug, and qualify manufacturing solutions. - Provide hands-on technical support during prototype builds, engineering validation, process qualification, and production ramp. - Travel domestically and internationally up to 25% to support development builds, tooling and equipment qualification, and production ramp. QUALIFICATIONS: - Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or a related technical field. - 5+ years of manufacturing engineering experience supporting product development and moderate- to high-volume manufacturing. - Ability to operate independently in fast-paced product development and manufacturing environments with limited technical oversight. - Strong experience applying DFM, DFA, and DFX principles during product development, with demonstrated ability to influence product designs for manufacturing. - Strong proficiency in SolidWorks, including detailed mechanical design, assemblies, drawings, and fixture design best practices. - Strong knowledge of GD&T, datum structures, tolerance analysis, tolerance stack-ups, and dimensional inspection methods. - Experience developing and qualifying manufacturing processes for small electromechanical or battery-powered electronic products. - Experience with manufacturing technologies including adhesives, heat staking, injection-molded plastics, and automated and manual assembly. - Strong understanding of injection-molded plastic part design principles, tooling considerations, defect modes, and their interaction with downstream assembly processes. - Experience designing and executing DOEs, process characterization studies, capability analyses, and structured failure investigations. - Strong hands-on mechanical/electrical and analytical problem-solving skills with the ability to independently develop solutions to complex product and manufacturing challenges. - Experience working directly with contract manufacturers, equipment vendors, tooling suppliers, and cross-functional product development teams. This role is based in the WHOOP office located in Boston, MA. The successful candidate must be prepared to relocate if necessary to work out of the Boston, MA office.   Interested in the role, but don’t meet every qualification? We encourage you to still apply! At WHOOP, we believe there is much more to a candidate than what is written on paper, and we value character as much as experience. As we continue to build a diverse and inclusive environment, we encourage anyone who is interested in this role to apply.   WHOOP is an Equal Opportunity Employer and participates in E-verify https://www.e-verify.gov/ to determine employment eligibility. It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.   The WHOOP compensation philosophy is designed to attract, motivate, and retain exceptional talent by offering competitive base salaries, meaningful equity, and consistent pay practices that reflect our mission and core values.   At WHOOP, we view total compensation as the combination of base salary, equity, and benefits, with equity serving as a key differentiator that aligns our employees with the long-term success of the company and allows every member of our corporate team to own part of WHOOP and share in the company’s long-term growth and success.   The U.S. base salary range for this full-time position is $150,000 - $195,000. Salary ranges are determined by role, level, and location. Within each range, individual pay is based on factors such as job-related skills, experience, performance, and relevant education or training.   In addition to the base salary, the successful candidate will also receive benefits and a generous equity package.   These ranges may be modified in the future to reflect evolving market conditions and organizational needs. While most offers will typically fall toward the starting point of the range, total compensation will depend on the candidate’s specific qualifications, expertise, and alignment with the role’s requirements.