• Senior R&D Engineer, DFX

    Actalent (Sunnyvale, CA)


    Job Title: Senior R&D Engineer, DFX

    Job Description

    This mechanical engineering role focuses on applying Design for Excellence (DFX) principles, particularly Design for Manufacturability (DFM), to enhance product development by reducing manufacturing costs, improving quality, and streamlining production. The engineer will collaborate with contract manufacturers to create scalable processes through adaptable systems that efficiently increase production volumes while maintaining quality and controlling expenses. A strong understanding of current design technology is essential, as the engineer will be involved in new product development projects to establish high-quality mechanical designs, rapid prototype development, design input requirements, risk documentation, test methods, and verification testing. This role requires interfacing across multiple departments including manufacturing, production, supply chain, quality, regulatory, and other engineering teams.

    Responsibilities

    + Develop mechanical designs for new product development projects and current product enhancements focusing on manufacturable, scalable, and cost-effective solutions.

    + Build and test preliminary ideas using rapid prototyping tools to evaluate design concepts and iterate toward final solutions.

    + Conduct risk management documentation, including hazard analysis and failure modes and effects analyses (FMEA/FMECA), to identify and mitigate design and process risks.

    + Lead root cause analysis investigations for product failures and test anomalies using structured approaches such as 5 Whys, fishbone diagram, design of experiments (DOE), and statistical analysis.

    Essential Skills

    + Expertise in medical device design.

    + Proficiency in Design for Excellence (DFX) and Design for Manufacturability (DFM).

    + Experience in cost optimization and design control.

    + Skills in prototype development, root cause analysis, FMEA, FMECA, and DHF.

    Additional Skills & Qualifications

    + Proficiency in CAD tools, such as SolidWorks.

    + Experience with CNC Machining and 3D Printing.

    Work Environment

    The work environment involves collaboration across multiple departments including manufacturing, production, supply chain, quality, and regulatory engineering teams. The role requires the use of technologies like CAD tools and rapid prototyping equipment in a setting that emphasizes scalability and cost-effectiveness.

    Pay and Benefits

    The pay range for this position is $126000.00 - $220200.00/yr.

     

    Medical, dental, and vision insurance provided at no cost for employee-only coverage401(k) matching planPaid Time Off – starting at 3 weeks per yearCompetitive salary with opportunities for career growthEmployee stock optionsLife & AD&D and long term disability insuranceEducation assistance

     

    Workplace Type

     

    This is a fully onsite position in Sunnyvale,CA.

     

    Application Deadline

     

    This position is anticipated to close on Jul 25, 2025.

    About Actalent

    Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500.

     

    The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

     

    If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing due to a disability, please email [email protected] (%[email protected]) for other accommodation options.