Hardware Development Engineer

Role Overview

Ensurge is seeking a Hardware Development Engineer to design and execute equipment upgrades and hardware improvements across our pilot manufacturing lines. Reporting to the Head of Equipment & Facilities Engineering, this individual contributor role works hand-in-hand with equipment engineering, maintenance, and manufacturing engineering to turn recurring tool problems and process needs into designed, built, and validated hardware solutions.

This role spans the full lifecycle of a hardware improvement - from identifying an opportunity or chronic issue, through concept and CAD design, fabrication or procurement, installation, and validation on the line.

Key Responsibilities

Equipment Upgrade Design & Execution

• Design, build, and install upgrades to existing production and pilot equipment - from targeted fixes to full subsystem redesigns.
• Translate chronic equipment issues, reliability data, and process requirements into concrete hardware design solutions, in partnership with Equipment Engineering.
• Own upgrade projects end-to-end: concept, design, fabrication/procurement, installation, and validation.
• Design and improve custom hardware, mechanisms, and fixtures to solve problems that off-the-shelf equipment doesn't address.

Hardware & Mechanical Design

• Create detailed CAD models and drawings for fixtures, brackets, tooling, and custom equipment hardware.
• Apply sound mechanical design and tolerancing practices for equipment operating in vacuum, cleanroom, or precision handling environments.
• Specify components, materials, and vendors, and manage fabrication or outside machining through to delivery.
• Build and test prototypes before committing designs to full installation.

Cross-Functional Collaboration

• Work daily with Equipment Engineering and Maintenance to prioritize upgrades based on uptime, MTBF/MTTR, and safety impact.
• Partner with Manufacturing Engineering to ensure hardware changes support process requirements, throughput, and repeatability.
• Coordinate with Technology (R&D) on tool modifications needed to support new processes or process development.
• Align with Quality and EHS on any hardware change that affects process control, traceability, or safety.

Testing, Validation & Documentation

• Validate new hardware and upgrades against defined acceptance criteria before handoff to production.
• Document designs, drawings, change history, and installation/maintenance procedures so upgrades are sustainable and repeatable.
• Support root cause analysis on equipment issues and translate findings into design changes, not just workarounds.
• Feed lessons learned from each upgrade into equipment standards and future tool designs.

What We're Looking For

• 3-10+ years of experience in mechanical or hardware design engineering, ideally supporting manufacturing or process equipment (semiconductor, battery, thin-film, electronics, or similar).
• Strong CAD proficiency (SolidWorks or equivalent) and solid fundamentals in mechanical design, tolerancing, and materials selection.
• Hands-on experience designing, building, and installing fixtures, tooling, or equipment hardware - not just modeling on a screen.
• Comfortable working directly on the equipment floor, troubleshooting alongside technicians and engineers.
• Able to move a design from concept to installed hardware quickly, without sacrificing rigor.

Preferred Qualifications

• Experience with vacuum systems, deposition tools, roll-to-roll/web handling, or cleanroom equipment.
• Exposure to controls, sensors, or basic automation (PLC, motion control) as part of hardware upgrades.
• Experience supporting pilot lines or first-of-kind manufacturing equipment.
• Background in laser processing, precision assembly, or material handling equipment.
• BS/MS in Mechanical Engineering, Mechatronics, or a related engineering discipline, or equivalent practical experience.

Personal Attributes

• Hands-on and resourceful - comfortable designing a solution and then helping build and install it.
• Synergized with the team - seeks input from equipment engineers, technicians, and process owners rather than designing in isolation.
• Ownership mentality - sees an upgrade through from idea to validated, working hardware.
• Disciplined problem solver - fixes root causes, documents thoroughly, and builds toward repeatable standards.
• Low ego, collaborative, and comfortable in a fast-moving, scaling environment.

Salary Range: $121,000-$150,000. The base salary range is specific to California. The salary of the final candidate selected for this role will be determined by a variety of factors, including, but not limited to, internal equity, experience, education, specialty, and training.