Mechanical & Thermal Design Engineer – XR Headset

Company: US-Based Technology Company

Work Location: Fun Republic Area, Andheri West, Mumbai

Employment Type: Full-Time | In office

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

📌 Mechanical & Thermal Design Engineer – XR Headset (Andheri West)
🏢 Screens player
📍 Andheri West