Mechanical Engineer for Cable Mechanism Improvement

We are looking for an experienced mechanical engineer to help review, validate, and qualify a proposed improvement to a retractable cable mechanism for a physical product. The goal is not only to assess whether the proposed mechanism improvement will work reliably, but also to determine whether it can be manufactured consistently, cost-effectively, and at scale. The ideal candidate should have experience with retractable cable systems, spring-loaded mechanisms, compact mechanical assemblies, and design for manufacturing. Project Scope: We have a proposed improvement to an existing retractable cable mechanism and need an engineer to help determine whether the design is mechanically sound and manufacturable. This includes evaluating the mechanism, identifying potential risks or failure points, reviewing the manufacturing process, and recommending changes needed before prototyping or production. We are looking for someone who can provide practical engineering feedback, not just CAD support. Responsibilities: Review the proposed retractable cable mechanism improvement Evaluate whether the mechanism is mechanically feasible and reliable Assess spring/retraction behavior, cable routing, friction, durability, tension, and user feel Identify possible failure modes, wear issues, assembly challenges, or tolerance concerns Review the proposed manufacturing process for the mechanism and related components Recommend suitable materials, tolerances, and production methods Evaluate manufacturability for processes such as injection molding, CNC machining, stamping, die casting, 3D printing, or assembly-based production Provide DFM/DFA feedback to improve cost, reliability, and assembly efficiency Recommend prototype or validation testing methods Suggest design changes needed to qualify the mechanism for manufacturing Help prepare engineering notes, drawings, or documentation for manufacturers if needed Required Experience: Mechanical engineering background Experience with retractable cable, cord reel, badge reel, tape measure, spool, spring-loaded, or similar mechanisms Strong understanding of mechanical tolerances, friction, wear, material selection, and small mechanical assemblies Experience qualifying or validating mechanical design improvements Experience reviewing manufacturing processes and DFM/DFA requirements CAD experience with SolidWorks, Fusion 360, Inventor, or similar Ability to clearly explain engineering risks, tradeoffs, and recommendations Experience with consumer products or compact mechanical products is a plus Deliverables May Include: Engineering review of the proposed mechanism improvement Feasibility assessment of the retractable cable design Manufacturing process review Risk and failure mode feedback Recommended design changes or improvements Material and manufacturing process recommendations Prototype testing or validation plan Annotated CAD feedback, drawings, or engineering notes if needed Summary report suitable for internal review or manufacturer discussion Ideal Candidate: The ideal candidate has previously worked on small mechanical mechanisms involving cables, springs, spools, gears, ratchets, reels, or compact enclosures. We are looking for someone practical and detail-oriented who understands how to qualify a mechanical design for real-world use and production. To Apply, Please Include: Examples of similar retractable, spring-loaded, cable, or spool-based mechanisms you have worked on Your experience qualifying mechanical design improvements Your experience reviewing manufacturing processes and DFM/DFA CAD software you use Manufacturing processes you are familiar with Your approach to evaluating whether a proposed mechanism is ready for prototyping or production Project Type: One-time project with potential for continued support through prototyping, testing, and manufacturing. Budget: Open to fixed-price or hourly proposals depending on experience.