{"id":2259313,"url":"https://alion.io/job/synchron-principal-mechanical-engineer","title":"Principal Mechanical Engineer","company":{"id":63210,"name":"Synchron","domain":"synchron.com","url":"https://alion.io/company/synchron","size_band":"201-500","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"ADP","truth_index":{"grade":"B","score":75,"open_postings":3,"ghost_share":0,"stale_share":1,"repost_share":0,"time_to_fill_p50_days":null,"computed_at":"2026-10-12T06:55:09Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"lead","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["San Diego, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":175000,"max":200000,"currency":"USD","period":"year","gross":null,"usd_annual":200000},"salary_estimate":null,"experience_years_min":null,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[],"status":"live","first_seen_at":"2026-10-10T22:25:00Z","employer_posted_date":"2026-10-10","last_verified_at":"2026-10-12T02:01:01Z","board_verified":true,"closed_at":null,"days_open":1,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":1},"description":"We are seeking a Principal Mechanical Engineer to help develop the next generation of Synchron’s implantable medical device technology. This is a highly hands-on technical leadership role focused on solving challenging mechanical design, materials, packaging, and manufacturing problems at the intersection of miniaturized electronics, polymers, and medical devices.\nYou will lead the development of novel approaches to overmolding, encapsulation, mechanical packaging, and miniature mechanical systems, taking concepts from early prototypes through design verification and manufacturing readiness. The work requires creativity, strong engineering fundamentals, and a willingness to explore solutions beyond traditional medical-device design approaches.\nThis is an opportunity to work on technology where mechanical engineering decisions directly enable entirely new device capabilities.\nResponsibilities\nLead mechanical development of next-generation medical device components and assemblies from concept through verification and transfer to manufacturing.\nDevelop innovative overmolding and encapsulation approaches for miniaturized electronic and electromechanical assemblies.\nDesign and prototype miniature mechanical systems and deployment mechanisms with challenging dimensional, material, and reliability requirements.\nEvaluate polymers, elastomers, adhesives, coatings, and other materials for mechanical performance, manufacturability, biocompatibility, and long-term reliability.\nDevelop mechanical architectures that integrate electronics, flexible components, interconnects, and structural elements within highly constrained form factors.\nUse analytical methods, simulation, prototyping, and benchtop testing to characterize mechanical performance and guide design decisions.\nIdentify potential failure modes and drive design improvements through testing, root-cause analysis, and design iteration.\nPartner closely with electrical, microfabrication, systems, manufacturing, quality, and clinical teams.\nWork with external suppliers and manufacturing partners to develop specialized materials, tooling, molding, and fabrication processes.\nProvide technical leadership and mentorship while remaining deeply involved in hands-on engineering and prototyping.\nDevelop solutions consistent with medical-device design controls, risk management, verification, and manufacturing requirements.\nQualifications\nBS or MS in Mechanical Engineering, Biomedical Engineering, Materials Engineering, or a related discipline.\nSignificant industry experience developing complex mechanical systems, with experience operating at a Principal, Staff, or equivalent technical leadership level.\nMedical device development experience is required, including experience working within a regulated product-development environment.\nDemonstrated experience designing and developing overmolded, encapsulated, polymer-based, or highly integrated mechanical assemblies.\nStrong understanding of mechanical design, material selection, tolerance analysis, prototyping, and design for manufacturing.\nExperience developing small, mechanically complex systems where packaging, materials, and manufacturing processes are tightly coupled.\nStrong experimental mindset with demonstrated ability to rapidly prototype, test, learn, and iterate.\nAbility to independently tackle ambiguous technical problems and develop novel solutions rather than relying solely on established approaches.\nExcellent communication skills and ability to work effectively across highly multidisciplinary engineering teams.\nNice to Have\nExperience developing implantable medical devices or other devices requiring long-term interaction with the body.\nExperience with implantable-grade polymers, elastomers, adhesives, coatings, or encapsulation systems.\nExperience with micro-mechanical systems, deployment mechanisms, flexible assemblies, catheters, leads, or other highly constrained medical-device architectures.\nKnowledge of accelerated aging, mechanical reliability, hermeticity or moisture-ingress considerations, and long-term material performance.\nExperience developing manufacturing processes involving molding, precision assembly, laser processing, bonding, or other specialized fabrication 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now","p_open":1,"p_active":0.86,"p_room":1,"age_days":1,"expected_fill_days":38,"reasons":["conf:4","win:early"],"computed_at":"2026-10-12T06:55:09Z"},"pay":{"stated_usd_annual":200000,"is_top_pay":true},"html_url":"https://alion.io/job/synchron-principal-mechanical-engineer","json_url":"https://alion.io/job/synchron-principal-mechanical-engineer.json","meta":{"generated_at":"2026-10-12T08:54:31Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per 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