Senior Mechanical Design Engineer

About Level Zero Level 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. Founded 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. We'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. We're looking for a Senior Mechanical Design Engineer to lead the mechanical architecture of Level Zero's wearable medical devices, from early concept through to design transfer and volume manufacture. Working directly with the founding team and a multidisciplinary engineering group, you'll set the mechanical direction for highly miniaturised, body-worn products, making the key decisions on architecture, materials, manufacturing processes and risk. This is a hands-on senior role for someone who wants to own the mechanical design of a medical wearable end to end, while mentoring others and shaping how we develop products as we grow.

What you'll do

Own and lead the mechanical architecture of Level Zero's wearable medical devices. Drive miniaturisation and integration, working with electronics, sensing and industrial design to package complex functionality into small, comfortable, body-worn form factors. Set mechanical design standards, CAD practices, drawing conventions and design review processes for the engineering team. Lead the design of injection moulded, overmoulded and precision components from concept through to production release. Define mechanical requirements, design specifications and architecture documentation, and ensure traceability within the design history file. Lead tolerance analysis and statistical tolerancing for critical assemblies to ensure robust performance and manufacturability at scale. Own mechanical risk management, leading DFMEA activities and contributing to PFMEA and overall product risk files. Define and oversee verification and validation strategies, including reliability, environmental, ingress, drop, wear and life-cycle testing. Lead root cause investigations into complex mechanical failures and drive effective, data-led design improvements. Champion human-centred design, leading human factors studies, usability evaluations and user research, and ensuring wearability, comfort and ease of use are designed in from the start. Select and manage external suppliers, moulders, tooling vendors and contract manufacturers, and lead tooling trials, pilot builds and design transfer. Balance performance, usability, reliability, manufacturability, regulatory requirements and cost across the product lifecycle. The ideal candidate must have Master's degree with 4+ years of industry experience in mechanical engineering, biomedical engineering or a related discipline. A track record of taking medical devices or consumer wearables from concept through to volume manufacture. Experience leading the mechanical design of highly miniaturised or densely integrated products. Expert CAD and drafting skills, including complex assemblies and surfacing, with a strong command of engineering drawings, GD&T and manufacturing tolerances. Extensive experience designing injection moulded plastic components for volume manufacture, including overmoulding, multi-shot or insert moulding. Experience leading tolerance stack analysis and applying statistical tolerancing to critical assemblies. Experience designing sealed, leak-tight or ingress-protected assemblies and developing associated test methods. Strong knowledge of assembly methods including snap fits, heat staking, ultrasonic and laser welding, adhesives and overmoulding. Experience leading DFMEA, contributing to PFMEA and applying structured risk management in line with ISO 14971. Experience working within an ISO 13485 or equivalent quality system, including design controls, change control, product release and PLM systems. Experience defining and executing V&V plans and mechanical test methods. Experience managing external suppliers, tooling vendors and contract manufacturers, including tooling trials and production transfer. Proven ability to lead structured root cause analysis on complex mechanical failures. Experience designing products with user needs at the centre of development. Experience mentoring engineers and leading technical design reviews. Strong communication skills and the ability to influence across multidisciplinary engineering teams and with senior stakeholders.

Nice to have

Experience designing skin-adhered or continuously worn medical devices (e.g. CGMs, patch pumps, cardiac monitors) Experience designing pumps, valves, diaphragms, microfluidics or other fluid-handling mechanisms Experience with IEC 60601, ISO 10993 biocompatibility or IEC 62366 usability engineering Experience designing precision mechanical mechanisms, such as applicators or insertion mechanisms Experience with sterilisation-compatible design and material selection Familiarity with Design of Experiments (DOE) and statistical data analysis Experience with FEA for structural, thermal or fatigue assessment Experience with rapid prototyping, machining and 3D printing Prior work in a start-up or small company environment Experience building or scaling an engineering team Who You Are We value culture as much as we value te