Mechanical & Thermal Design Engineer – XR Headset
Company: US-Based Technology Company
Work Location: Fun Republic Area, Andheri West, Mumbai
Employment Type: Full-Time | On-Site
Experience: Freshers Welcome
Education: B.E./B.Tech – Mechanical Engineering, Mechatronics, Product Design, Manufacturing Engineering or related discipline
About the Opportunity
A US-based technology company is hiring engineers in Mumbai to develop a next-generation immersive entertainment headset.
We are looking for a Mechanical & Thermal Design Engineer who is passionate about designing physical products and wants to work on the actual body, internal structure, ergonomics and cooling architecture of an advanced XR headset.
You will work closely with electronics, optics, embedded software, industrial design and manufacturing teams to transform electronic and optical components into a comfortable, lightweight and manufacturable consumer device.
Fresh graduates with strong CAD, mechanical design, 3D-printing or product-development projects are encouraged to apply.
Key Responsibilities
Headset Mechanical Design
Design the physical architecture of the XR headset.
Create internal layouts for processor boards, displays, optics, cameras, sensors, battery and speakers.
Design mounting structures and component brackets.
Develop front housing, rear housing and internal structural components.
Define screw locations, clips, connectors and assembly mechanisms.
Design parts considering manufacturing tolerances.
Work closely with electronics and optics engineers to ensure correct component placement.
Headset Body & Industrialization
Responsibilities include:
Develop 3D CAD models.
Create detailed engineering drawings.
Design plastic components.
Select appropriate engineering plastics and materials.
Work with prototype and injection-molding vendors.
Review vendor tooling proposals.
Evaluate ready-made headset bodies where appropriate.
Modify existing vendor chassis for product requirements.
Support development of custom parts when required.
For early production, we may use a ready-made or semi-custom XR chassis, so you will also evaluate whether existing vendor designs can be modified instead of unnecessarily designing every component from zero.
Ergonomics & Comfort
An entertainment headset may be worn continuously for an entire movie, making comfort extremely important.
You will work on:
Overall headset weight
Front/rear weight balance
Centre of gravity
Facial pressure distribution
Head strap geometry
Face cushion/interface
Nose clearance
Ventilation
Different head sizes
Prescription-glasses compatibility
Long-duration wearing comfort
You will conduct physical fit tests and convert user feedback into mechanical improvements.
Thermal Engineering
High-performance XR processors and displays generate significant heat inside a compact enclosure.
You will help design the thermal-management system.
Responsibilities include:
Identify major heat-generating components.
Design thermal paths from processor/display electronics to the enclosure.
Evaluate heat sinks, graphite sheets, thermal pads, heat spreaders and heat pipes.
Evaluate passive versus active cooling.
Design airflow and ventilation paths.
Measure surface temperatures.
Conduct sustained-load thermal tests.
Prevent excessive heat reaching the user's face.
Work with embedded/software engineers on thermal throttling requirements.
The objective is to maintain performance while keeping the headset safe, quiet and comfortable.
Prototype Development
You will create and evaluate physical prototypes using technologies such as:
3D Printing → CNC → Vacuum Casting → Prototype Tooling → Injection Molding
You will:
Prepare CAD files for prototypes.
Work directly with prototype vendors.
Assemble prototype bodies.
Measure component fit and tolerances.
Identify interference and assembly problems.
Modify designs based on test results.
Maintain design revisions.
Design for Manufacturing
You will work with the Manufacturing/Process Engineer to ensure the headset can eventually be assembled efficiently.
This includes:
Design for Manufacturing (DFM)
Design for Assembly (DFA)
Injection-molding considerations
Draft angles
Wall thickness
Ribs and bosses
Snap fits
Screw bosses
Tolerance stack-up
Tool accessibility
Assembly sequence
Serviceability
The goal is not simply to create a beautiful CAD model—it must be possible to manufacture thousands of identical units reliably.
Mechanical Validation
You will help develop tests for:
Drop resistance
Strap durability
Button durability
USB-C connector durability
Housing strength
Repeated assembly/disassembly
Heat deformation
Lens/display mounting stability
Transportation vibration
Long-duration wearing comfort
Failures will be analyzed and translated into design improvements.
Tools & Skills
Candidates should have exposure to one or more of:
SolidWorks Creo CATIA Fusion 360 AutoCAD Siemens NX
Knowledge of the following is desirable:
3D CAD
Engineering drawings
GD&T fundamentals
Materials
Plastics
Injection molding
Manufacturing tolerances
Heat transfer
Thermal management
Mechanical prototyping
3D printing
Freshers Are Welcome
Professional XR experience is not required.
We are particularly interested in fresh graduates who have built things.
Good projects could include:
Robotics Drones Wearables Consumer Products 3D-Printed Devices Automotive Components Product Enclosures Mechanical Prototypes Smart Devices AR/VR Projects
Candidates should be comfortable showing their CAD models, prototypes, college projects or portfolio during the interview.
What We Look For
We are looking for engineers who:
Enjoy building physical products.
Are comfortable repeatedly prototyping and improving designs.
Understand that appearance and engineering must work together.
Think about the user as much as the CAD model.
Can work closely with electronics and software engineers.
Are willing to work hands-on with prototypes.
Can communicate directly with manufacturing vendors.
Want to see something they designed become a real commercial product.
Freshers strongly encouraged
We value hands-on projects, engineering fundamentals, curiosity and problem-solving ability more than years of experience. If you have designed and built real mechanical products during college or independently, we encourage you to apply.
Work Location: In person
