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.