Senior Mechanical Engineer, Packaging

At WHOOP, we're on a mission to unlock human performance and healthspan. WHOOP empowers users to perform at a higher level through a deeper understanding of their bodies and daily lives. WHOOP is looking for a Senior Mechanical Engineer, Packaging to lead the design, development, validation, and manufacturing release of next-generation packaging systems for WHOOP products and accessories. You are a proactive engineer with strong problem-solving skills, technical creativity, and attention to detail. You thrive in a fast-paced environment and independently drive packaging design solutions with sound engineering judgement, balancing the user experience, quality, cost and scalability. You will collaborate closely with Mechanical Engineering, Industrial Design, Manufacturing, Quality, Operations, Program Management, Product, Brand, and Creative. You will work directly with global suppliers and contract manufacturers to develop, qualify, and ramp packaging solutions into mass production. WHOOP operates with urgency because our mission demands it. We build products for people who push their limits—and we hold ourselves to the same standard. If you’re energized by complex challenges, hands-on development, cross-functional collaboration, and the opportunity to ship packaging at scale, this role will push you—and reward you. RESPONSIBILITIES: - Own packaging components and assemblies from concept through manufacturing release - Lead packaging design, development, qualification, and production ramp for WHOOP products and accessories. - Create SolidWorks CAD models and packaging structures to support design exploration, prototyping, manufacturing development, and qualification - Create and maintain technical documentation, including 3D files, 2D drawings, BOMs, specifications, and Engineering Change Orders (ECOs) - Own component selection and BOM accuracy, balancing manufacturability, cost, quality, sustainability, and supply chain readiness - Partner with Industrial Design teams to translate visual design intent into manufacturable packaging solutions across structure, material, print, graphics, color and finish - Build prototypes and perform hands-on assembly for engineering evaluation, proof-of-concept development, design validation, and drive cross-functional decisions - Perform root cause analyses to identify and resolve design, manufacturing, quality, and field issues - Establish and improve packaging engineering best practices, documentation standards, and design review processes - Travel internationally up to 20% QUALIFICATIONS: - BS or MS in Mechanical Engineering, Industrial Design Engineering, or a related field - 5+ years of experience developing packaging at scale, ideally for high volume consumer products or consumer electronics - Strong SolidWorks CAD experience in part design, assemblies, configuration management, drawing creation, and efficient integration of DFM feedback - Proficiency in Adobe Illustrator for packaging dielines, graphic layout review, print documentation - Experience creating and maintaining detailed 2D drawings, BOMs, ECOs, and component-level documentation. - Experience working directly with domestic and overseas suppliers through development, tooling, qualification, production ramp, and ongoing production support - Experience designing packaging for high volume manufacturing, including automated and manual assembly processes - Strong knowledge of packaging materials such as paperboard, molded pulp, corrugate, labels, films, adhesives, trays, inserts, and protective structures - Working knowledge of print and graphic production techniques, including color and finish control, tolerancing, inspection criteria, and methods for maintaining consistency at scale - Skilled at hands-on prototyping, model making, assembly, and troubleshooting of packaging concepts - Strong organizational and communication skills, with the ability to work effectively across disciplines in a fast-paced environment. This role is based in the WHOOP office located in Boston, MA. The successful candidate must be prepared to relocate if necessary to work out of the Boston, MA office.   Interested in the role, but don’t meet every qualification? We encourage you to still apply! At WHOOP, we believe there is much more to a candidate than what is written on paper, and we value character as much as experience. As we continue to build a diverse and inclusive environment, we encourage anyone who is interested in this role to apply.   WHOOP is an Equal Opportunity Employer and participates in E-verify https://www.e-verify.gov/ to determine employment eligibility. It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.   The WHOOP compensation philosophy is designed to attract, motivate, and retain exceptional talent by offering competitive base salaries, meaningful equity, and consistent pay practices that reflect our mission and core values.   At WHOOP, we view total compensation as the combination of base salary, equity, and benefits, with equity serving as a key differentiator that aligns our employees with the long-term success of the company and allows every member of our corporate team to own part of WHOOP and share in the company’s long-term growth and success.   The U.S. base salary range for this full-time position is $140,000 - $195,000. Salary ranges are determined by role, level, and location. Within each range, individual pay is based on factors such as job-related skills, experience, performance, and relevant education or training.   In addition to the base salary, the successful candidate will also receive benefits and a generous equity package.   These ranges may be modified in the future to reflect evolving market conditions and organizational needs. While most offers will typically fall toward the starting point of the range, total compensation will depend on the candidate’s specific qualifications, expertise, and alignment with the role’s requirements.