Senior Mechanical Engineer, Packaging

About the role

WHOOP is on a mission to unlock human performance and healthspan, and this role is central to that ambition as you lead the design, development, validation, and manufacturing release of next-generation packaging systems for WHOOP products and accessories. You are a proactive problem-solver with strong technical creativity and meticulous attention to detail, thriving in a fast-paced environment where you independently drive packaging design solutions while balancing user experience, quality, cost, and scalability through sound engineering judgment. You will collaborate closely with Mechanical Engineering, Industrial Design, Manufacturing, Quality, Operations, Program Management, Product, Brand, and Creative teams, working directly with global suppliers and contract manufacturers to develop, qualify, and ramp packaging solutions into mass production. WHOOP operates with urgency because the mission demands it, building products for people who push their limits while holding yourself to the same high standard, so if you are 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 with meaningful impact.

Key facts

What you'll do

• Own packaging components and assemblies from concept through manufacturing release, ensuring every detail aligns with WHOOP's performance standards.
• Lead packaging design, development, qualification, and production ramp for WHOOP products and accessories from initial concept to high-volume execution.
• Create SolidWorks CAD models and packaging structures to support design exploration, prototyping, manufacturing development, and qualification activities.
• Create and maintain technical documentation, including 3D files, 2D drawings, BOMs, specifications, and Engineering Change Orders (ECOs) with precision and clarity.
• Own component selection and BOM accuracy, balancing manufacturability, cost, quality, sustainability, and supply chain readiness for optimal outcomes.
• 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 driving cross-functional decisions based on real-world testing.
• Perform root cause analyses to identify and resolve design, manufacturing, quality, and field issues, implementing corrective actions that prevent recurrence.
• Establish and improve packaging engineering best practices, documentation standards, and design review processes to elevate the overall capability of the organization.
• Travel internationally up to 20% to support global suppliers, contract manufacturers, and cross-functional initiatives that ensure seamless execution.
• Partner with manufacturing teams to optimize line layouts, automation compatibility, and manual assembly processes for efficient production flow.
• Evaluate and qualify new packaging materials and suppliers, ensuring compliance with regulatory requirements and internal quality standards.
• Support durability and reliability testing of packaging under real-world shipping, handling, and environmental conditions to protect products in transit.
• Drive packaging cost reduction initiatives without compromising user experience, quality, or scalability, aligning with company financial and sustainability goals.
• Communicate effectively with cross-functional stakeholders, translating technical requirements into actionable plans that keep projects on schedule.

Requirements

• BS or MS in Mechanical Engineering, Industrial Design Engineering, or a related field from an accredited institution.
• 5+ years of experience developing packaging at scale, ideally for high volume consumer products or consumer electronics with complex requirements.
• Strong SolidWorks CAD experience in part design, assemblies, configuration management, drawing creation, and efficient integration of DFM feedback to accelerate development.
• Proficiency in Adobe Illustrator for packaging dielines, graphic layout review, print documentation, and ensuring visual and functional accuracy.
• Experience creating and maintaining detailed 2D drawings, BOMs, ECOs, and component-level documentation that support manufacturing and quality processes.
• Experience working directly with domestic and overseas suppliers through development, tooling, qualification, production ramp, and ongoing production support to ensure alignment.
• Experience designing packaging for high volume manufacturing, including automated and manual assembly processes that meet throughput and quality targets.
• Strong knowledge of packaging materials such as paperboard, molded pulp, corrugate, labels, films, adhesives, trays, inserts, and protective structures for diverse applications.
• Working knowledge of print and graphic production techniques, including color and finish control, tolerancing, inspection criteria, and methods for maintaining consistency at scale across multiple markets.
• Skilled at hands-on prototyping, model making, assembly, and troubleshooting of packaging concepts to validate designs quickly and effectively.
• Strong organizational and communication skills, with the ability to work effectively across disciplines in a fast-paced environment while managing multiple priorities.
• Willingness to relocate to the WHOOP office in Boston, MA, and to travel internationally as required to support global operations and supplier relationships.
• Ability to adhere to strict timelines and quality standards while maintaining detailed records and documentation for regulatory and audit purposes.
• Commitment to following company policies, procedures, and safety guidelines in all aspects of packaging design and execution.

Nice to have

• Preferred items are not specified in the provided source, so no additional Nice to have qualifications are listed.

Practical notes

• Travel: Up to 20% international travel may be required.
• Eligibility: Must be able to work in Boston, MA, or relocate to the Boston office as necessary.
• Employment eligibility verification will be conducted in accordance with company policy and legal requirements.