Senior Mechanical Engineer

Align Technology is a leader in intraoral scanning, developing advanced opto‑electromechanical systems used by clinicians worldwide. Our products combine consumer‑electronics‑level design with the quality, reliability, and regulatory rigor of medical devices. As a Senior Mechanical Engineer, you will help shape the mechanical technologies behind next‑generation scanning platforms.

In this role, you will own the mechanical architecture and design of a complete electromechanical module, working closely with cross‑functional partners to deliver robust, manufacturable, and high‑performance products. You will be a key technical contributor in R&D, leading mechanical decision‑making, resolving complex engineering challenges, and acting as an escalation point across the product lifecycle.

This is a hands‑on senior individual contributor role with significant technical influence, focused on innovation, problem solving, and engineering excellence.

Key Responsibilities

• Own mechanical architecture, design, and integration of complex electromechanical modules within R&D

• Drive mechanical design decisions, trade‑offs, and risk mitigation across thermal, structural, and packaging domains

• Manage, review, and technically guide work performed by external mechanical designers and contractors

• Develop mechanical solutions for consumer‑electronics‑like products, balancing performance, reliability, cost, and manufacturability

• Lead and participate in technical design reviews, providing clear recommendations and direction

• Own hands‑on prototyping activities, including first system assembly, bring‑up, debugging, and iteration

• Collaborate closely with EE, Quality, Manufacturing, Program/Product Management, and external suppliers

• Support supplier engagement, DFM discussions, and technical problem resolution

• Perform hands‑on engineering work, including CAD design, tolerance analysis, and lab‑based testing and failure analysis

• Act as a mechanical escalation point, stepping in to resolve complex issues when needed, including downstream support to NPI or engineering teams as required

Skills, Knowledge & Expertise

• BSc in Mechanical Engineering

• 7+ years of hands‑on mechanical engineering experience in R&D environments

• Proven ownership of complex electromechanical systems or modules

• Strong experience in:

• Thermal design of electronic systems

• Plastics and injection‑molded part design (including DFM)

• Sheet metal and CNC‑machined components

• Electronics packaging (PCBAs, connectors, thermal interfaces)

• Strong communication skills with the ability to influence cross‑functional teams

• Fluent English (written and verbal)

• Solid experience working with external suppliers and manufacturing partners

• Provide technical leadership and design oversight for external mechanical designers and contractors

• Demonstrated ability to lead design reviews and drive technical decisions

• High proficiency with SolidWorks (or equivalent), GD&T, and tolerance stack‑ups

• Hands‑on lab experience, including testing, troubleshooting, and failure analysis

• Ability to prepare clear technical documentation and present design reviews and recommendations to broad, cross‑functional forums

Nice to have

• Experience in medical devices or regulated products

• Background in reliability or verification engineering

• Experience designing tooling or test fixtures in an R&D context

• Familiarity with FMEA and PLM/ECO workflows