Staff Mechanical Engineer, Communications​ Hardware (Relocation Assistance Available)

Title: Staff Mechanical Engineer, Communications​ Hardware (Relocation Assistance Available) Location: Boston, Massachusetts, United States

About Axon 911

Axon 911 brings together Prepared and Carbyne under Axon. Together, we are creating the only platform that combines modern 911 infrastructure with an AI intelligence layer—helping public safety agencies move faster, make better decisions, and deliver better outcomes in the moments that matter most.911 is the backbone of public safety, yet the professionals behind it have long been held back by outdated technology. Axon 911 is here to change that. Joining this team means more than taking a job—it means helping shape the future of emergency response and building a safer, more connected world.

Your Impact

We are seeking a Staff Mechanical Engineer, Communications​ Hardware to own the mechanical design and development of next-generation, mission-critical hardware from concept through high-volume production.

Join us as a founding member of our Axon 911 hardware team, you will have significant ownership across the mechanical development lifecycle, helping establish the technical foundation and engineering standards needed to scale compact, ruggedized, wireless-connected devices that public safety professionals carry and rely on in the field every day.

You will partner closely with Industrial Design (ID), Electrical Engineering (EE), Radio Frequency (RF) Engineering, Product Management, and manufacturing teams to translate product requirements into robust, production-ready mechanical designs. You will balance competing constraints across durability, sealing, antenna and RF performance, thermal management, battery integration, size, weight, ergonomics, and industrial design while driving designs from early concepts through mass production.

What You’ll Do

Mechanical Design & Development

• Own mechanical design from concept through high-volume production for compact, ruggedized, wireless-connected hardware.
• Develop mechanical designs that balance product requirements across size, weight, durability, sealing, thermal performance, RF performance, manufacturability, and cost.
• Design complex mechanical components and assemblies using plastic injection molding, stamped metal, die casting, machining, adhesives, and bonded joints.
• Build and analyze high-fidelity proof-of-concept prototypes and validate designs through FEA, tolerance analysis, and physical testing.

Ruggedization & Product Integration

• Design for demanding field environments, including drop, shock, vibration, long-term durability, and IP66/IP68 dust and water ingress protection.
• Own electro-mechanical integration across PCB/PCBA, flex circuits, batteries, antennas, and other internal components.
• Develop passive thermal-management solutions to dissipate heat from electronics while maintaining compact product form factors.
• Design for carry and wear ergonomics, including belt-, holster-, and body-mounted form factors and one-handed operation.

RF, Antenna & Industrial Design Integration

• Partner with RF and electrical engineers to integrate antennas and wireless systems, including antenna placement, keep-out zones, RF-transparent material selection, and EMI/EMC shielding.
• Develop mechanical structures compatible with RF performance and FCC/IC certification requirements.
• Partner closely with Industrial Design to preserve product aesthetics, ergonomics, and UX intent without compromising durability, sealing, thermal performance, RF performance, or manufacturability.
• Resolve competing mechanical, electrical, RF, and industrial design constraints through analysis, prototyping, testing, and engineering judgment.

Design Verification, Validation & Risk Mitigation

• Translate product requirements into clear, quantifiable mechanical engineering requirements and validation targets.
• Develop and execute mechanical verification plans across environmental, structural, thermal, ingress, and durability requirements.
• Perform tolerance analysis, FEA, and physical testing to identify design risks and drive mitigation before production.
• Participate in cross-functional design reviews and clearly communicate technical risks, tradeoffs, and recommendations.

Manufacturing & Production

• Partner with external consultants, vendors, manufacturers, and internal operations teams to drive DFM/DFA and production readiness.
• Drive part and assembly tolerance management to ensure robust, repeatable designs for high-volume manufacturing.
• Support engineering builds and product maturation through EVT, DVT, PVT, certification, and manufacturing ramp.
• Travel domestically and internationally as needed to support vendors, manufacturing partners, engineering builds, and production readiness.

What You Bring

Experience & Technical Leadership

• 12+ years of mechanical product design experience, ideally within ruggedized, portable, wearable, or other compact electronic products, with a proven track record taking hardware from concept through EVT/DVT/PVT and high-volume manufacturing.
• 5+ years of technical leadership experience, including providing technical direction to teams of 3+ mechanical engineers.
• Bachelor’s degree in Mechanical Engineering or equivalent experience.

Mechanical Design & Ruggedization

• Deep experience designing plastic injection-molded, stamped metal, die-cast, machined, adhesive, and bonded components and assemblies, with strong proficiency in Creo or comparable 3D CAD software.
• Strong expertise in DFM/DFA, tolerance analysis, FEA, prototyping, and physical validation, including designing to ruggedization standards such as MIL-STD-810 and IP66/IP68.
• Experience designing compact products around carry and wear ergonomics, including belt-, holster-, or body-mounted form factors and one-handed operation.

Electro-Mechanical, RF & Thermal Integration

• Experience integrating PCB/PCBA, flex circuits, batteries, antennas, and other electro-mechanical components within compact electronic devices.
• Experience designing wireless or connected hardware, including antenna integration, keep-out zones, RF-transparent materials, EMI/EMC shielding, and mechanical considerations for FCC/IC certification.
• Experience developing passive thermal-management solutions and balancing battery, power, runtime, size, weight, and thermal constraints.

Cross-Functional Development & Manufacturing

• Proven ability to preserve Industrial Design and UX intent while balancing mechanical, electrical, RF, durability, manufacturing, and certification requirements.
• Experience partnering with external consultants, vendors, and manufacturing partners through DFM/DFA, engineering builds, and production ramp.
• Strong ability to translate product requirements into quantifiable engineering deliverables, resolve competing design constraints, and communicate technical decisions across cross-functional teams.
• Flexibility to travel globally roughly once per month (15%+), alongside domestic trips when required to support manufacturing and vendor operations.

Work Location

This position offers a hybrid schedule, requiring team members to work onsite at one of our regional hubs, located in New York City, Boston, or Scottsdale, Arizona - Tuesday through Friday.

• Relocation Assistance: Relocation support is available for qualified candidates who are currently based in the U.S., authorized to work for a U.S. employer, and open to relocating closer to one of our regional hubs.
• Fully Remote Eligibility: Full-time remote eligibility will be evaluated on a case-by-case basis to accommodate specific needs.

Benefits that Benefit You

• Competitive salary and 401k with employer match
• Discretionary paid time off
• Paid parental leave for all
• Medical, dental, and vision plans
• Fitness Programs
• Emotional & Mental Wellness support
• Learning & Development programs
• And yes, we have snacks in our offices

Benefits listed herein may vary depending on the nature of your employment and the location where you work.

Pay Transparency
Axon offers a comprehensive total compensation package, which includes base salary, a generous annual bonus, and company equity.
The starting base annual pay for this role is between $108,750.00 - $189,750.00 excluding annual bonuses and equity, depending on your geographic market. The actual base salary will vary based on several factors, including level, function, training, transferable skills, work experience, business needs, and location—often a combination of these elements.

Our benefits are designed to support you physically, financially, and emotionally—through life’s major milestones and in your everyday moments. To learn more about our benefits, please visit www.axon.com/careers/benefits.