Mechanical Design Engineer

Mechanical Design Engineer

Location: Billerica, MA (On-site)

Salary: $80,000–$120,000 per annum

Employment Type: Full-time

We’re working with an innovative advanced materials company developing next-generation thermal management solutions for the semiconductor and electronics industries. As demand for more powerful computing and advanced semiconductor packaging continues to grow, effective thermal management is becoming increasingly important.

They’re looking for a Mechanical Design Engineer to join their team in Billerica, Massachusetts, supporting the development, prototyping and testing of high-performance thermal interface materials (TIMs).

This is an excellent opportunity for an early-career mechanical engineer to work on practical engineering challenges, develop their CAD and testing capabilities, and gain exposure to advanced semiconductor packaging programmes. You’ll work closely with experienced engineers, contributing to product development and generating the technical data needed to demonstrate performance and support customer qualification.

The role offers exposure to projects involving hyperscalers, original design manufacturers (ODMs) and outsourced semiconductor assembly and test providers (OSATs), with the opportunity to take on greater customer-facing technical responsibility as your experience develops.

Key Responsibilities

• Mechanical Design: Create CAD models, assembly drawings and fabrication documentation to support the integration of liquid-metal-based thermal interface materials into customer-specific electronic packages.
• Prototyping & Testing: Build and instrument package mock-ups and assembly fixtures, assessing design feasibility through mechanical, thermal and reliability testing.
• Thermal Analysis: Set up and conduct thermal and mechanical tests, analyse the resulting data, and prepare clear technical reports documenting findings.
• Fabrication & Supplier Coordination: Work with internal workshop resources and external vendors to coordinate component fabrication and ensure project timelines are maintained.
• Customer Qualification Support: Assist senior engineers with sample builds, test data packages and technical materials for application notes and design guides.
• Requirements Capture: Help document customer specifications and constraints, including geometry, mechanical loads, assembly requirements, operating environments, thermal budgets and reliability standards.
• R&D & Continuous Improvement: Collaborate with the wider R&D team to improve product performance, refine designs and support ongoing development.
• Technical Documentation: Maintain accurate CAD files, design records, test results and documentation throughout the customer qualification process.

Required Skills & Experience

• A Bachelor's or Master's degree in Mechanical Engineering or a closely related discipline.
• 0–3 years of relevant professional experience. Applications from candidates with suitable internships, co-ops or hands-on engineering projects are encouraged.
• Proficiency in 3D CAD modelling and engineering drawings, using SolidWorks, Creo or similar software.
• A working understanding of Geometric Dimensioning and Tolerancing (GD&T).
• Practical experience with prototyping, laboratory equipment, fixture assembly, testing and troubleshooting.
• A sound understanding of heat transfer and mechanical engineering fundamentals, with an interest in thermal design and electronics packaging.
• Strong analytical skills and the ability to interpret experimental data and communicate findings through technical documentation.
• Good communication skills, a proactive approach to learning, and the ability to work collaboratively in a fast-moving engineering environment.

Desirable experience:

• Semiconductor packaging, electronics assembly or thermal interface materials.
• Reliability testing, including temperature cycling (TCT), high-temperature storage (HTS) or highly accelerated temperature and humidity stress testing (uHAST).
• Finite Element Analysis (FEA).
• Data analysis using Excel, Python or MATLAB.

Salary & Benefits

• $80,000–$120,000 annual base salary.
• Health, dental and vision insurance, with 75% of premiums covered for employees and dependants.
• Unlimited paid time off.
• 14 paid holidays per year.
• Up to 10% travel to customer and supplier sites.