Mechanical Design Engineer-SolidWorks

About the Company We are developing a digital smart scope for security applications. The device integrates a 4K Sony IMX678 camera, SoC (6 TOPS NPU), laser rangefinder, 25mm thermal camera, and a 0.49" Micro OLED display into a ruggedized monolithic aluminum housing. We have completed an initial mechanical design through collaboration between our in-house engineering team and external consultants. We are now looking for a dedicated full-time mechanical engineer to join us on an ongoing basis to refine, improve, and evolve this design toward a production-quality product. Role Overview You will work directly with our engineering team (English communication) as a core member of the mechanical development track. Your primary responsibility is to take our existing SolidWorks assembly and drive continuous improvement — making the design lighter, stronger, more manufacturable, and thermally optimized — while maintaining IP67 ruggedization and defense-grade durability. This is a hands-on engineering role, not a consulting role. We expect daily progress, active communication, and ownership of assigned tasks. Key Responsibilities 1. Design Improvement & Refinement - Review and improve the existing AIRYS housing SolidWorks assembly - Reduce part count and simplify assembly where possible - Optimize wall thicknesses, rib structures, and internal geometry for weight reduction while maintaining structural integrity - Improve DFM (Design for Manufacturability) for 5-axis CNC milling in 7075-T6 aluminum - Refine all external features: lens bezels, button recesses, vent placement, battery door, Picatinny rail mount 2. Structural Analysis (FEA) - Perform static and dynamic stress analysis using SolidWorks Simulation or equivalent - Verify housing can withstand repeated recoil shock of 500G+ peak - Analyze Picatinny mount stress under clamping and recoil loads - Validate screw boss and Helicoil insert pull-out strength - Document analysis results with clear pass/fail criteria 3. Thermal Analysis - Simulate heat dissipation path from SoC through aluminum L-bridge sled to external housing fins - Verify SoC junction temperature remains below 80 degrees C under full AI processing load - Analyze aerogel insulation effectiveness between SoC zone and OLED display module (target: OLED panel 60 degrees C maximum) - Evaluate cooling fin geometry and recommend improvements if needed - Perform thermal simulation under operating temperature range (-30 to +80 degrees C ambient) 4. Tolerance & Sealing Analysis - Define and verify O-ring groove geometry for IP67 sealing at all interfaces (main housing joins, battery door, USB-C port door, GORE vent) - Perform tolerance stack-up analysis for critical assemblies (lens alignment, PCB mounting, display alignment) - Verify LRF optical axis parallel alignment tolerance (target: 0.5 mrad maximum) 5. Documentation - Maintain and update SolidWorks assembly files as changes are made - Produce and revise 2D technical drawings (PDF + DWG) with GD&T callouts for all modified parts - Update Bill of Materials (BOM) to reflect design changes - Write brief engineering change notes for each significant modification 6. Ongoing Support - Support prototyping phase — review 3D printed mock-up results and recommend adjustments - Collaborate with PCB team on mechanical-electrical integration (connector placement, FPC routing clearances, thermal pad contact areas) - Support transition from prototype to pilot production design Current Design Technical Specifications Overall dimensions: 180mm (L) x 80mm (W) x 90mm (H) Housing material: 7075-T6 aluminum, CNC monolithic Surface finish: Type III Hard Anodize, Matte Black Sealing standard: IP67 — O-ring at all joins + GORE membrane vent Shock resistance: 500G+ peak Operating temperature: -30 to +80 degrees C Required Skills and Experience Must Have: - SolidWorks 2021 or later — proficiency in Part, Assembly, and Drawing modules (please state your version in your proposal) - SolidWorks Simulation (FEA) — static stress, modal, and thermal analysis - CNC machining design — experience designing parts for 3-axis and 5-axis milling - GD&T — ability to produce complete 2D drawings with proper tolerance callouts - IP67 sealing design — O-ring groove geometry, surface finish requirements - Strong English communication — daily written updates required Strongly Preferred: - Experience with ruggedized electronics enclosures for defense, industrial, or outdoor equipment - Familiarity with thermal interface materials (TIM, gap pads, heat pipes, aerogel) - Experience with DFM/DFA for low-to-medium volume production (100 to 500 units) - Background in optical instrument housing design Nice to Have: - Experience with MIL-SPEC or IP-rated product development - Familiarity with Helicoil and threaded insert engineering - Knowledge of anodizing and surface treatment specifications Work Arrangement - Hours: 40 hours per week, full-time - Schedule: Flexible — overlap with Korea Standard Time (UTC+9) preferred for daily check-ins - Communication: Daily written status update required (3 to 5 bullet points). Weekly video call with engineering team. - Tools: SolidWorks (your own license required), Upwork Time Tracker - File sharing: Google Drive or Dropbox provided by client - Language: English for all technical communication and documentation How to Apply Please include ALL of the following in your proposal. Proposals missing any item will not be reviewed. 1. Portfolio Share 2 to 3 examples of CNC aluminum enclosures you have personally designed to a manufacturing-ready state. Must include 2D technical drawings — renders only are not acceptable. Defense, industrial, or outdoor equipment examples are strongly preferred. 2. Software State your SolidWorks version and confirm you have SolidWorks Simulation (FEA) available. 3. Availability Confirm you are available for 40 hours per week and can start within 2 weeks. State your time zone. 4. Required Technical Question — Answer required for proposal to be reviewed: "For an aluminum housing designed to IP67 with a face seal O-ring, what are the key parameters you would specify for the O-ring groove (cross-section diameter, groove width, groove depth, surface roughness Ra), and why is compression ratio important?" 5. Brief Approach In 3 to 5 sentences, describe how you would approach a thermal simulation for a device where a 10W SoC must stay below 80 degrees C while an OLED display 30mm away must stay below 60 degrees C.