Staff Mechanical Design Engineer, R&D (Hybrid)

$104,600 - $157,250/Yr

Insulet Corporation - Acton, MA

Full-time - Mid Level

Hybrid - Acton, MA

Miscellaneous Manufacturing

About the position

Insulet is seeking a highly skilled Staff Mechanical Design Engineer to join our dynamic design team, focusing on the development of next-generation wearable medical devices. This role is pivotal in driving innovation and leadership within the organization, as the engineer will be responsible for designing and developing advanced insulin delivery technologies that enhance the lives of patients with diabetes. The Staff Mechanical Design Engineer will engage in a variety of tasks, including rapid prototyping, feasibility testing, and optimizing designs for manufacturability, all while ensuring that the products meet the highest standards of safety and reliability. In this position, the engineer will work closely with cross-functional teams to integrate device subsystems and support the transition of commercial-ready products into a highly automated production environment. The role requires a strong foundation in mechanical engineering principles, as well as experience in end-to-end product design within the medical device sector. The ideal candidate will thrive in a fast-paced environment, tackling complex technical challenges and contributing to the development of innovative solutions that align with Insulet's mission of improving patient outcomes. The Staff Mechanical Design Engineer will also play a key role in mentoring junior engineers and interns, fostering a collaborative and innovative work culture. This position is hybrid, requiring three days a week in the office, with the potential for additional on-site work depending on project needs. Travel is minimal, estimated at 10% or less, allowing for a balanced work-life dynamic.

Responsibilities

• Generate next-generation insulin delivery technologies (inclusive of ideation, design, and filing of intellectual property)
• Design device subsystems using CAD software and support full system integration efforts
• Analyze design solutions using engineering software tools and statistical methods
• Identify and mitigate risks associated with device functionality, reliability, safety, COGs and manufacturing scalability
• Design, setup and execute or guide feasibility tests
• Prototype and test subsystems using in-house rapid prototyping and testing equipment
• Work on platform extensions which utilize Insulet's core pump technologies
• Work with and lead cross-functional teams and efforts within the organization
• Work within final assembly manufacturing environment(s) and assist in early-stage process development and manufacturing optimization to ensure products meet design intent
• Work with and manage external suppliers, conduct DFM reviews, and go onsite as needed
• Conduct and lead competitor technology tear-down studies
• Present engineering takeaways and proposed solutions to R&D, operations and commercial stakeholders
• Develop or guide development of fixtures and simple tooling to assemble and test early-stage prototypes
• Mentor junior engineers, co-ops and interns

Requirements

• Strong foundation in mechanical engineering fundamentals and first principles
• Knowledgeable in the design and joining of plastic components for bio-compatible applications
• Advanced CAD capabilities - complex assemblies, surfacing and multi-body modeling experience, preferred
• Ethical, responsible, and data-driven decision-maker
• Ability to effectively communicate (verbal/written) at multiple levels of an organization
• Knowledge and experience in design of experiments (DOE) and medical device V&V
• Knowledge of Statistical Process Control (SPC), GD&T; Lean, Six Sigma, preferred
• Knowledge of infusion pumps and subcutaneous injection systems, preferred
• PC skills - MS Office Suite, SolidWorks, and ePDM required
• Ansys, LabVIEW, a preferred
• Ability to organize and judge priorities, as well as oversee and delegate responsibilities to other engineering staff / team members, when necessary
• Knowledge of Design for manufacturing/cost (DFM/C) and automated assembly experience, a plus

Nice-to-haves

• Experience in the design of injection molded components, stampings and machined components
• Experience in the design of disposable, bio-compatible fluid paths and/or container solutions
• Experience with electromechanical devices (PCBA, batteries, interconnects, layout)
• Experience in high volume product design (>10 million units per year)
• A track record of generating novel ideas / IP

Benefits

• Hybrid working arrangements
• Competitive salary range
• Opportunities for professional development
• Support for a healthy work-life balance
• Collaborative work culture
• Mentorship opportunities