Staff Mechanical Engineer
Confirmed on the employer's own hiring board on Oct 14, 2026. First seen by Alion on Aug 18, 2026.
About Orion
Orion is building the next generation of intelligent sleep technology-thermal regulation, advanced sensing, and beautifully engineered hardware designed to improve sleep quality and long-term health. We’re ramping toward mass production and scaling globally. Mechanical Engineering is core to how our system functions, feels, and performs night after night.
About the Role
We’re looking for a Staff Mechanical Engineer to own and architect critical mechanical systems across the Orion Sleep System. This role operates at a system level, driving architecture, design quality, manufacturability, and execution from early concept through mass production. You’ll work deeply across thermal systems, fluid routing, enclosures, CMF, mechanisms, and high-precision assemblies, while influencing engineering standards, design direction, and execution velocity. This is a hands-on technical leadership role embedded with Operations, Quality, EE, FW, Reliability, and our global manufacturing partners.
What You’ll Own
Lead design of TEC-based thermal systems, fluid routing, enclosures, and integrated mechanical assemblies across the Orion Sleep System
Own detailed CAD, tolerancing, GD&T, and stack-up analysis
Drive CMF alignment, surface quality, and tooling readiness
Translate system requirements into robust, production-ready mechanical designs
Work directly with global manufacturing partners across plastics, sheet metal, machining, and final assembly
Guide tooling development, design changes, and build readiness for EVT / DVT / PVT and MP
Support on-site factory builds, failure analysis, and process optimization
Define and execute validation plans for durability, lifecycle reliability, thermal stability, noise, fit, and cosmetic quality
Partner with Reliability, QA, and Operations to drive root-cause analysis and corrective actions
Maintain drawings, specifications, ECOs, and build documentation
Collaborate closely with EE and FW on system integration, routing constraints, and sensor placement
Partner with Product, Ops, and Supply Chain to balance cost, schedule, and manufacturability
Lead design reviews and technical trade-offs with clarity and ownership
What We’re Looking For
8+ years of mechanical engineering experience in consumer hardware or integrated electromechanical systems
Proven system-level ownership across complex mechanical architectures
Deep expertise in plastics, sheet metal, mechanisms, thermal systems, and high-volume manufacturing
Expert-level CAD proficiency (SolidWorks or equivalent) with strong DFM/DFA and GD&T skills
Track record of taking products from concept → EVT → DVT → PVT → MP
Hands-on engineering mindset-comfortable in labs, factories, and design reviews
Strong technical communication and ability to influence across teams without direct authority
Experience with thermoelectric (TEC/Peltier) systems or thermal-regulation platforms is a plus
Experience working with Asian contract manufacturers is a plus
Strong sensitivity to CMF and cosmetic quality standards is a plus
Why Orion
Mechanical Engineering at Orion is a first-order function. As a Staff Engineer, you’ll help define the technical foundation of a category-defining sleep platform and influence how the product scales globally. Your work will directly impact product performance, customer experience, and long-term platform strategy.