{"id":748734,"url":"https://alion.io/job/levelzerohealth-mechanical-design-engineer","title":"Mechanical Design Engineer","company":{"id":679227,"name":"Level Zero Health","domain":"levelzerohealth.com","url":"https://alion.io/company/levelzerohealth","size_band":"51-200","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Lever","truth_index":null},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"junior","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["London, United Kingdom"],"countries":["GB"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":46000,"max_usd":74000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":119},"experience_years_min":2,"visa_sponsorship":false,"relocation_package":false,"has_equity":true,"technologies":[{"name":"FMEA","optional":false},{"name":"GD&T","optional":false},{"name":"Design of Experiments","optional":true},{"name":"ISO 13485","optional":true},{"name":"ISO 14971","optional":true},{"name":"Verification & Validation","optional":true}],"status":"live","first_seen_at":"2026-07-10T15:31:15Z","employer_posted_date":"2026-07-10","last_verified_at":"2026-11-01T21:05:50Z","board_verified":true,"closed_at":null,"days_open":114,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":114},"description":"About Level Zero\nLevel Zero is pioneering next-generation biosensor technology for precise, real-time monitoring of critical endocrine biomarkers. Recognised as one of the top 20 startups across all categories worldwide at TechCrunch Disrupt 2024 - and backed by top-tier organisations like SOSV and Entrepreneur First - we're pushing the boundaries of biochemistry and nanotechnology to revolutionize personalised health.\nFounded by two seasoned engineers, we bring extensive experience in R&D, technical innovation, and commercial strategy to transform the way people monitor their health. Our mission is bold: to revolutionise health management by delivering clinical-grade data directly to individuals, wherever they are.\nWe're seeking driven innovators to join us in pushing the boundaries of biosensing and health tech, making personalised health monitoring a reality for everyone. To achieve this ambitious vision, we're assembling the best team in the world - dedicated to turning cutting-edge science into life-changing, real-world solutions.\nWe're looking for a Mechanical Design Engineer to help design, prototype and industrialise the mechanical and plastics architecture of Level Zero's wearable medical devices. Working closely with the founding team and multidisciplinary engineers, you'll take concepts from CAD-driven design through DFM/DFA, tooling and verification, building miniaturised components and assemblies that are reliable, comfortable to wear and manufacturable at scale. This is a hands-on role at the intersection of precision mechanical design, injection moulding, miniaturisation and medical product development.\n\nWhat you'll do\nOwn the mechanical design and development of plastic and mechanical components for wearable medical devices, including enclosures, skin-interface parts, internal mechanisms and sealed or fluid-handling subsystems.\nDesign compact, highly integrated assemblies, working with electronics and sensing teams to fit complex functionality into small, body-worn form factors.\nProduce high-quality 3D CAD models, assemblies and engineering drawings to manufacturing standards.\nPerform tolerance analysis and tolerance stack-ups to ensure robust product performance and manufacturability.\nCreate detailed design specifications, engineering requirements and mechanical architecture documentation.\nDevelop, refine and execute verification test methods to evaluate product performance and reliability. Plan and conduct engineering testing, analyse results and iterate designs based on data.\nLead mechanical investigations, identify root causes of failures and implement effective design improvements.\nApply human-centred design practices by conducting human factors studies, usability evaluations and user research sessions, translating findings into actionable product and design improvements, particularly around wearability and comfort.\nWork closely with external suppliers and manufacturing partners to develop production-ready components.\nSpecify and qualify bought-in components and work with suppliers to integrate them into the product.\nCollaborate closely with electronics, systems, quality, manufacturing and industrial design teams.\nBalance technical performance, usability, reliability, manufacturability and cost throughout the design process.\nContribute to early-stage R&D, collaborating with engineering leadership to define and refine future design iterations.\nWhat You Bring\nThe ideal candidate must have:\nMaster's degree with 2 - 4 years of industry experience in mechanical engineering, biomedical engineering or a related discipline.\nExperience developing medical devices, wearables or other compact consumer or electromechanical products.\nExperience designing products with user needs at the centre of development.\nExperience designing miniaturised or highly integrated mechanical assemblies.\nExperience designing sealed or leak-tight assemblies and developing associated test methods.\nExcellent CAD and drafting skills including complex assemblies and surfacing where appropriate, with a strong understanding of engineering drawings, GD&T and manufacturing tolerances.\nExperience performing tolerance stack analysis and applying statistical tolerancing where appropriate.\nExperience creating engineering documentation including design specifications and product requirements.\nExperience applying DFM, DFA and DFMA principles.\nExperience working with external suppliers, manufacturers and tooling vendors.\nExperience creating and refining mechanical test methods and verification plans.\nExperience with DFMEA, PFMEA and structured engineering risk management.\nStrong experience designing injection moulded plastic components for volume manufacture. Experience attending tooling trials, evaluating moulded parts and resolving manufacturing issues.\nProven ability to troubleshoot mechanical failures using structured root cause analysis.\nUnderstanding of assembly methods including snap fits, heat staking, ultrasonic welding, adhesives or overmoulding.\nExperience with engineering change control, product release processes and PLM systems.\nStrong communication skills and ability to work within multidisciplinary engineering teams.\nComfortable taking ownership of significant subsystems while working with appropriate technical guidance.\nNice to have:\nExperience designing skin-adhered or continuously worn medical devices\nExperience designing pumps, valves, diaphragms, microfluidics or other fluid-handling mechanisms\nKnowledge of ISO 13485, ISO 14971 or equivalent quality systems\nExperience with verification and validation (V&V) testing\nExperience with reliability, environmental, fatigue or life-cycle testing\nExperience designing precision mechanical mechanisms\nExperience with rapid prototyping, machining and 3D printing\nFamiliarity with Design of Experiments (DOE) and statistical data analysis\nExperience supporting pilot builds, manufacturing scale-up and production transfer\nBasic FEA experience for structural or thermal assessment\nPrior work in a start-up or small company environment\nPrior work in medical device development\nWho You Are\nWe value culture as much as we value technical expertise, creating an environment that's equal parts collaboration, curiosity, and fun.\nWe're a fast-paced, mission-driven young team on a quest to make a lasting impact, fueled by uncompromising integrity, unwavering support for one another, and the thrill of exploring uncharted territories. Our passion for excellence drives everything we do, and we welcome individuals who share our commitment to shaping the future.\nIf our vision excites you, here are the qualities we look for:\nYou live and breathe integrity, tackling challenges with honesty and transparency.\nYou're a self-starter who loves diving into the unknown, collaborating on complex problems, and taking full ownership of results.\nYou excel at open, clear communication and see every piece of feedback as a springboard for growth-especially in a science and data-focused environment.\nYou're motivated by creating real impact, particularly when it comes to advancing human health.\nYou strike a balance between independence and collaboration, knowing when to seek support or invite others to join in.\nYou're confident in defending your ideas, while also valuing respectful, constructive debate as a path to better solutions.\nYou thrive in the dynamic atmosphere of a startup, constantly evolving your skill set and fearlessly applying what you learn.\nWhat we offer\nA full-time role with a competitive salary and equity options, reflecting our value in your expertise and potential.\nAn environment where you'll collaborate directly with the founding team at a leading biosensor startup, gaining access to industry experts and thought leaders.\nThe chance to grow with us, including ample opportunities for leadership, career advancement, and exploration.\nTravel to New York and other potential sites for R&D purposes.\nThe excitement of working on cutting-edge technology, shaping strategic decisions, and driving innovation at an early-stage venture alongside a superstar 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