Manufacturing Mechanical Engineer
Confirmed on the employer's own hiring board on Nov 3, 2026. First seen by Alion on Jul 2, 2026. Sesame AI scores A on the Alion truth index.
About Sesame
Sesame believes in a future where computers are lifelike - with the ability to see, hear, and collaborate with us in ways that feel natural and human. With this vision, we're designing a new kind of computer, focused on making voice agents part of our daily lives. Our team brings together founders from Oculus and Ubiquity6, alongside proven leaders from Meta, Google, and Apple, with deep expertise spanning hardware and software. Join us in shaping a future where computers truly come alive.
About the Role
As a Manufacturing Mechanical Engineer at Sesame, you'll own the mechanical process and fixturing that turns our hardware designs into repeatable, high-yield builds. You'll work directly with our contract manufacturers and tooling partners in Asia - defining assembly processes, specifying and reviewing fixtures, running DOEs, and driving failure analysis when builds don't behave.
This is a hands-on role for someone who may spend up to 90% of your day in MCAD. You'll spend your time in CAD defining fixtures and process tooling, on the floor validating them, and in the data understanding why a station is losing yield. You'll partner closely with Product Design, Test Engineering and Quality as we take products from EVT through mass production.
Responsibilities:
Design and develop assembly fixtures, jigs, and manufacturing tooling using 3D CAD and be comfortable designing assembly fixtures and process tooling yourself.
Serve as the primary point of contact for fabrication partners in Southeast Asia, and other international partners.
Procure, assemble, validate, maintain, and improve fixtures, jigs, and related equipment.
Troubleshoot manufacturing tooling issues to improve quality, yield, and throughput.
Manage external partners developing fixtures, jigs, test systems, and equipment.
Partner with Factory Operations leadership to achieve quality and operational goals.
Collaborate with automation vendors to deploy and optimize robotic manufacturing solutions.
Evaluate and implement new manufacturing technologies, equipment, and processes.
Support NPI and process development in collaboration with the U.S. engineering team.
Travel ~20% to suppliers and manufacturing partners to ensure successful execution.
Required Qualifications:
7+ years in mechanical engineering, manufacturing engineering, tooling, or related fields.
Have taken a consumer hardware product from prototype builds through to volume manufacturing
Have worked directly with contract manufacturers and can hold a technical line with their factory engineers.
Expert CAD skills and experience designing tooling, fixtures, jigs, or automated equipment
Strong understanding of materials (plastics, metals, adhesives) and manufacturing processes, including machining, injection molding, stamping, fabrication, and assembly.
Proven problem-solving ability with experience improving processes, quality, and yield.
Comfortable working with suppliers, fabrication partners, and engineering teams.
Bachelor’s degree in Mechanical Engineering or equivalent practical experience.
Preferred Qualifications:
Master’s degree in Mechanical Engineering or equivalent experience.
10+ years of experience in consumer electronics, precision manufacturing, or a related industry.
Experience bringing consumer electronic products from development through production.
Experience shipping wearable products with demanding industrial design, cosmetic, and quality requirements.
Sesame is committed to a workplace where everyone feels valued, respected, and empowered. We welcome all qualified applicants, embracing diversity in race, gender, identity, orientation, ability, and more. We provide reasonable accommodations for applicants with disabilities. Contact [email protected] for assistance.
Full-time Employee Benefits:
401 (k) max employer match: 3.5% of compensation
100% employer-paid health, vision, and dental benefits for you and your dependents
Unlimited PTO and sick time
Flexible spending account with employer matching up to $1,650/year (medical FSA)
Guardian Employee Assistance Program (EAP)
Opportunity to share in the company's success with competitive stock options
Benefits do not apply to contingent/contract workers.