About PepperBall
PepperBall is a global leader in non-lethal defense and compliance systems, dedicated to developing innovative solutions that protect lives, reduce risk, and empower non-lethal options for professionals in the field. Our products are trusted by law enforcement, corrections, and military organizations worldwide — and our commitment to innovation continues to push the boundaries of what’s possible in non-lethal technology.
About the Role
The Senior Mechanical Design Engineer is the technical lead and subject matter expert for PepperBall’s existing product portfolio, with a strong focus on launcher platforms and regulator-based systems. This role owns engineering support for product improvement, product maintenance, field issue resolution, quality improvement, and new supplier qualification efforts across current products.
The ideal candidate has strong mechanical engineering fundamentals, hands-on experience with pneumatic or regulator-based hardware systems, structured root cause analysis capability, and the ability to translate technical knowledge into clear documentation that improves product quality, consistency, and long-term portfolio reliability.
Key Responsibilities
Technical Ownership & Sustaining Engineering
Serve as the technical lead for PepperBall’s existing product portfolio, with primary ownership of launcher platforms, pneumatic systems, regulator-based assemblies, and related accessories.
Develop and maintain deep technical expertise in current launcher architectures, air systems, regulators, valves, fittings, feed systems, pressure vessels, sealing interfaces, and mechanical assemblies.
Own sustaining engineering workstreams for product improvements, design updates, part substitutions, lifecycle maintenance, corrective actions, and issue resolution on existing products.
Make independent engineering decisions on design tradeoffs, materials, manufacturing methods, tolerances, validation needs, and corrective actions for current products.
Create and review 3D CAD models, 2D drawings, tolerance stack-ups, engineering specifications, bills of material, and design documentation tied to existing product maintenance and improvement.
Identify practical design improvements that enhance durability, reliability, manufacturability, serviceability, safety, and field performance.
Launcher, Pneumatic & High-Pressure Air System Expertise
Act as the internal subject matter expert for launcher systems and compressed gas / high-pressure air systems used across the PepperBall portfolio.
Bring and further develop strong technical depth in pneumatic, compressed-gas, high-pressure air, regulator-based, fluid power, paintball, airgun, pneumatic tool, or directly adjacent product categories.
Understand the interaction between air source, regulator, valve, pressure delivery, projectile feed, launcher performance, and user handling in field conditions.
Evaluate performance issues involving pressure stability, leakage, velocity variation, air efficiency, feed reliability, durability, sealing performance, and component wear.
Support technical decision-making related to regulator selection, compressed air components, sealing systems, service requirements, and field maintenance needs.
Product Improvement, Quality & Supplier Support
Lead structured root cause analysis for design, manufacturing, supplier, assembly, and field issues using methods such as 5 Whys, Fishbone, fault tree analysis, test-to-failure, and data-driven troubleshooting.
Partner with Quality, Operations, Product Management, Customer Service, and suppliers to resolve field performance issues and drive corrective and preventive actions.
Develop and support validation, durability, reliability, and regression testing for product changes, supplier changes, component updates, and corrective actions.
Review test data, identify trends, communicate technical findings, and recommend appropriate design, process, supplier, or documentation changes.
Participate in Design FMEA and Process FMEA activities for existing products and translate identified risks into practical validation plans, design improvements, and quality controls.
Lead or support new supplier qualification efforts for existing portfolio components, including technical reviews, drawing updates, sample inspection, validation testing, and production readiness.
Collaborate with domestic and overseas contract manufacturers to ensure products are built to design intent and meet performance, quality, cost, and manufacturability requirements.
Lead engineering change requests, part substitutions, cost improvement initiatives, inspection criteria, finished goods testing, quality audits, and end-of-life component transitions without compromising product performance or quality.
Technical Documentation & Cross-Functional Leadership
Own and improve technical documentation for existing products, including drawings, specifications, test methods, inspection standards, service guidance, work instructions, and technical reference materials.
Document institutional knowledge on launcher systems, pneumatic and regulator-based systems, known failure modes, critical-to-quality characteristics, and maintenance requirements.
Create clear technical summaries, PowerPoint presentations, test reports, and recommendations for audiences ranging from engineering and operations to executives and external partners.
Work closely with Product Management to prioritize sustaining engineering work based on customer impact, field feedback, quality data, business risk, and portfolio strategy.
Participate in product demos, field testing, user feedback sessions, and customer issue reviews with law enforcement, corrections, military, and other end users.
Translate field feedback and customer issues into engineering requirements, test plans, design changes, maintenance actions, and supplier improvement activities.
Collaborate cross-functionally with Marketing, Sales, Operations, Quality, Customer Service, and Engineering to align technical decisions with customer expectations and business needs.
Provide technical mentorship and review support to engineers, project team members, and cross-functional partners.
Qualifications
- Bachelor’s degree in Mechanical Engineering or a related technical discipline.
- 6+ years of engineering experience in sustaining engineering, product design, product improvement, mechanical systems, pneumatic systems, fluid power, durable hardware, paintball, airgun, sporting goods, public safety, defense, or adjacent product categories.
- Technical depth with regulator-based systems, compressed gas systems, pneumatic mechanisms, or directly adjacent technologies; paintball launcher experience is strongly preferred.
- Strong understanding of mechanical design, pneumatics, pressure regulation, sealing systems, valves, fittings, tolerance stack-ups, materials, manufacturing processes, and product validation.
- Proven experience resolving design, manufacturing, supplier, and field issues through structured root cause analysis and data-driven problem solving.
- Experience qualifying new suppliers, evaluating alternate components, supporting engineering changes, and validating production readiness for existing products.
- Advanced 3D CAD modeling and 2D drafting capability using SolidWorks, Creo, Fusion 360, or similar software.
- Experience developing and reviewing engineering drawings, specifications, test methods, inspection criteria, and technical documentation.
- Experience with validation testing, durability testing, reliability testing, pilot builds, manufacturing support, and corrective action implementation.
- Working knowledge of Design FMEA, Process FMEA, DFM/DFA, and quality improvement methods.
- Experience collaborating with global contract manufacturers and suppliers.
- Ability and willingness to travel domestically and internationally to support supplier visits, product validation, manufacturing reviews, and field evaluations.
- Strong analytical, communication, documentation, and project management skills.
- Physical Requirements: Must be able to safely lift and move moderate-weight items (up to 30–40 lbs.) as required for prototype handling, product testing, and field evaluation.
Why PepperBall?
Work on mission-driven products that protect lives and reduce risk. Collaborate in a cross-functional, innovation-focused team environment. Drive organizational improvement and process maturity in a growing company. Engage in the full product lifecycle — from concept to field deployment.
Competitive compensation, comprehensive benefits, and opportunities for career growth within a rapidly expanding organization.
Equal Opportunity Employer: All applicants will be considered for employment without attention to race, color, religion, sex, sexual orientation, gender identity, national origin, veteran or disability status. Any offer of employment is contingent upon successful completion of a physical / drug test.
Pay: $115,000.00 - $140,000.00 per year
Benefits:
- 401(k)
- 401(k) matching
- Dental insurance
- Health insurance
- Health savings account
- Life insurance
- Paid time off
- Vision insurance
Application Question(s):
- Do you have experience with Pneumatic systems?
- Do you have knowledge and experience with 3D CAD?
- Have you done 2D drafting?
- Do you have experience resolving issues through Root Cause analysis?
- Have you sourced and vetted new suppliers and product?
- Have you successfully lead a team through concept, development, production and launch of product to market?
Education:
Experience:
- Mechanical engineering: 6 years (Required)
Ability to Commute:
- Lake Forest, IL 60045 (Required)
Work Location: In person
