Senior Mechanical Engineer

About REP: REP designs world-class, innovative gym equipment that is sold around the world, and we are now expanding into apparel, supplements, athletes, and events. REP was established in 2012 by two brothers who shared a deep passion for fitness. From our humble beginnings of selling bumper plates out of a small garage, REP has experienced remarkable growth, now occupying over 300,000+ square feet of office and distribution space in the USA and internationally. With a dedicated team of over 200+ fitness enthusiasts, our vision is to be the #1 Strength Brand in the World. Our commitment to innovation, customer service, and value sets us apart. 

We believe in building a culture centered around fitness, so we specialize in outfitting home gyms, commercial gyms, and strength and conditioning facilities. Our dedication to excellence has been recognized multiple times when we were featured in the Inc. 5000 fastest growing private companies in 2018 and 2021 and then voted the best home strength product launch in 2022 by Garage Gym Experiment.

Our team

works out together, and we regularly invite fitness superstars to join us. We organize fun

challenges

to test our limits - and the

limits of our equipment

. 

At REP, we continue to grow and bring new opportunities for those who want to be a part of a winning team. We firmly believe that being surrounded by like-minded individuals fuels creative energy and fosters a fun and collaborative work environment. 

This role is based in our state-of-the-art headquarters with a bright, spacious, shared workspace; scenic views of the Rocky Mountains; and a kitchen always stocked with healthy snacks, protein powder, and coffee.

 We offer a hybrid work environment with a minimum of three days in the office, but there’s flexibility about which days and hours.

Our Core Values: Think Like a Customer

- We empathize with our customers; understand the '

why'

behind every decision we make

Progress not Perfection

- We don't let perfect get in the way of

good

; we are better today than we were yesterday

Positive Attitude

- Be a

glass half-full

kind of person and remember to have fun

Teamwork without Ego

- We put the

team

above ourselves; we only win together

Take Initiative

- We

drive

momentum; if there is an opportunity to make us better, we want to hear it

About This Role: As a Senior Mechanical Engineer, you will be a senior technical leader on the REP engineering team, owning the mechanical design of our most complex products and product platforms from proof of concept to mass production. You will work closely with product line managers, industrial designers, project managers, and department leadership to execute the product roadmap and deliver innovative solutions for our customers. Projects at this level carry the highest technical risk and business impact, and you will be trusted to make, and defend, the critical design decisions. You will also raise the bar for the whole team by mentoring other engineers, setting design standards, and improving how we develop products. This role may include direct reports.

Essential Functions: I nclude the following. Other duties may be assigned.  

• Lead complex, high-impact projects and product platforms to completion with full ownership and minimal oversight, often managing multiple projects or engineers at the same time.

• Architect and design complex mechanisms and assemblies, including plastic injection molded parts, weldments, castings, and sheet metal, using 3D CAD (SolidWorks); develop design architectures that can be reused across product lines.

• Partner with Product Line Managers and department leadership to define customer and engineering requirements, assess technical feasibility, and influence the product roadmap; work with Industrial Designers to balance aesthetics with function and manufacturability.

• Develop engineering scope, schedule, cost, and resource estimates for new projects; identify risks early and communicate tradeoffs to leadership.

• Regularly mentor and develop engineers at all levels by delegating work, providing technical guidance, and leading design reviews; may manage direct reports.

• Serve as a technical authority in design reviews across the engineering team, ensuring designs are robust, safe, and manufacturable.

• Direct prototype builds and testing in our in-house prototyping shop and R&D lab.

• Lead FMEA and Risk Assessment sessions across product lines and own the resulting mitigation plans.

• Perform and review advanced FEA simulations, calculations, and tolerance analysis, including fatigue and dynamic loading, and verify the analysis work of other engineers.

• Define test methodologies and validation plans aligned with industry standards; lead root cause investigations on complex quality and field issues and drive corrective actions.

• Oversee the release of production drawings, bills of materials, and engineering change orders, and approve design changes for assigned product lines.

• Lead DFM (design for manufacturing) and cost reduction efforts with contract manufacturers; resolve escalated manufacturing issues and drive value engineering.

• Create and improve engineering standards, design guidelines, and best practices for the team.

• Drive innovation by generating novel concepts, evaluating new materials, technologies, and processes, and leading invention disclosures and intellectual property strategies for your projects.

Travel:

Up to 10% international travel.

What You Will Bring: To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• Proven ability to lead complex projects, and the engineers working on them, to on-time and on-cost launches with minimal oversight.

• Ability to set technical direction and make sound decisions with incomplete information, balancing performance, cost, schedule, and risk.

• Ability to mentor and develop engineers and give clear, constructive design feedback.

• Ability to interpret and apply test and design standards (ISO, ASTM, etc.); experience with fitness equipment standards such as ISO 20957 is a plus.

• Ability to solve ambiguous, multi-variable problems in situations where limited standardization exists.

• Ability to turn rough concepts into innovative, patentable designs.

• Mastery of first principles in engineering problems, including free body diagrams, stress, strain, deflection, fatigue, dynamic loading, and safety factors.

• 3D CAD expert (SolidWorks preferred) with advanced FEA skills (SolidWorks Simulation preferred) and the ability to review and verify the analysis of others.

• Expertise in GD&T and tolerance stack-up analysis.

• Experience with PDM and PLM systems; strong project management skills.

• Extensive experience with new product introduction (NPI) processes from concept to production, including work with overseas contract manufacturers.

• Deep knowledge of manufacturing processes such as machining, welding, casting, extrusion, forging, punching, and injection molding, and the cost drivers of each.

• Ability to explain complex technical topics clearly to engineers, leadership, and non-technical partners.

• Willingness to work hands-on with physical prototypes (bonus, if you have machine shop capabilities).

• Willing to meet early or late (1-2 calls weekly) with Asia counterparts. Travel to Asia as needed for project support and manufacturing issue resolution.

Education and/or Experience:

• Bachelor's degree from a four-year college or university in Mechanical Engineering or related Engineering field.

• Minimum 8+ years of engineering experience and a demonstrated track record of excellence in product design and development, with 4 or more products taken from concept to mass production, including at least one as the technical lead.

• Prior fitness industry or related consumer product experience- Preferred

• Experience mentoring or managing engineers or other technical disciplines- Preferred

Core Competencies: Action Oriented

- Taking on new opportunities and tough challenges with a sense of urgency, high energy, and enthusiasm.

Resourcefulness

- Securing and deploying resources effectively and efficiently.

Collaborates

- Building partnerships and working collaboratively with others to meet shared objectives.

Manages Ambiguity

- Operating effectively, even when things are not certain, or the way forward is not clear.

Optimizes Work Processes

- Contributing to effective and efficient processes with a focus on continuous improvement.

Communicates Effectively

- Developing and delivering multi-mode communications that convey a clear understanding of the unique needs of different audiences. 

Ensures Accountability

- Holding self and others accountable to meet commitments.

Cultivates Innovation

- Creating new and better ways for the organization to be successful.

What's in it for You:

Our commitment to quality and transparency applies not only to our products, but to our people. We are focused on creating a fun, exciting, collaborative space that’s centered around health and well-being. We empower everyone on our team to take control of their careers and balance their work and life in a modern, fast-paced environment.

We offer an

exceptional

compensation package which includes: 

Compensation base range: $125,000.00 - $155,000.00  annually with bonus potential

Day One Benefits!

• Medical, Dental, Vision (Competitive Benefits Packages Available) 

• Health Savings Account (HSA) with employer contributions 

• Flexible Spending Account (FSA) options 

• LTD/STD, Life and AD&D (100% premiums covered by REP)  

• 401k and Roth options with employer match up to 4% 

• Employee Assistance Program (EAP) 

Recharge Yourself! 

• 4 weeks of PTO accrued during your first year 

• 48 hours of sick leave annually 

• 7 paid company holidays with an additional floating holiday

• Paid Parental leave day 1

• Birthday - Paid day off 

Pumped-up Perks!

• Unique bonus structure that rewards exceptional individual performance as well as company-wide performance 

• Full access to employee gym 

• Employee discount on REP equipment, apparel and nutrition

• Daily snacks and drinks provided by REP (for onsite employees) 

• 'Fitness' casual attire 

• Company and team building events  

• Professional growth and development within the organization 

• LIFE-WORK balance 

Physical Requirements: The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. 

While performing the duties of this job, the employee is constantly required to sit and use hands to operate the telephone, type and operate the computer and mouse. Physical effort may include stooping, kneeling, touching, feeling, reaching, standing, walking, pushing, pulling, lifting, fingering, grasping, talking, hearing, and repetitive motions.  The employee is frequently required to talk, hear, and bend and twist their necks. The employee may occasionally lift and/or move up to 50 pounds and rarely lift and/or move up to 100 pounds assisted.  Specific vision abilities required by this job include close vision and distance vision. 

REP provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability, or genetics. In addition to federal law requirements, REP complies with applicable state and local laws governing nondiscrimination in employment in every location in which the company has facilities.  

This specification is intended to indicate the kinds of tasks and levels of work difficulty that will be required of positions that will be given this title and shall not be construed as declaring what the specific duties and responsibilities of any particular position shall be. It is not intended to limit or in any way modify the right of any supervisor to assign, direct, and control the work of employees under his/her supervision. The use of a particular expression or illustration describing duties shall not be held to exclude other duties not mentioned. Ability to competently perform all the essential duties of the position, with or without reasonable accommodation, demonstrated commitment to effective customer service delivery, and the ability to work productively as a member of a team or work group are basic requirements of all positions at REP.