Long-term Mechanical Interface Engineer (CAD + Materials + DFM + Durability) — Pickleball Paddle Prototype Ended

I’m hiring a long-term, hourly mechanical CAD / mechanical design engineer to act like a fractional CAD/ME lead for a modular pickleball paddle. This is not a one-time modeling task — it will be ongoing back-and-forth iterations (design → 3D print → test → revise) until the mechanism is reliable, then refined for manufacturing readiness.

This project is technically challenging and there isn’t one “right answer.” I’m optimizing for a premium, durable outcome — I want someone who thinks deeply about load paths, interface stiffness/shear transfer, materials behavior, friction/wear, tolerance strategy, and how performance changes over time (not just “make CAD that fits”).

Scope / What I Need:

Own and maintain a clean parametric CAD assembly (multi-part interface/mechanism + surrounding structure).

Design and iterate the mechanism so it is robust, repeatable, and user-friendly.

Provide prototype-ready deliverables for each iteration: STEP assemblies/parts + print-ready STLs (and native CAD), with brief notes on critical fits/clearances and what changed.

Once the design stabilizes, produce a manufacturer handoff package:

2D drawings with tolerances (GD&T where appropriate)

Materials/finish notes

BOM

Assembly + inspection notes

Materials / Manufacturing Context:

This is a performance sporting good. Prototyping will start with 3D printing (and CNC where needed). Final manufacturing method is not locked yet, but premium paddles commonly use carbon-fiber composite face skins with a polymer honeycomb-type core, plus adhesives/bonding and perimeter/edge structures. I’m looking for someone comfortable reasoning about how real production materials, bonding methods, and surface conditions affect stiffness, wear, and long-term performance.

CAD Tool:

Tool-flexible: SolidWorks, Fusion 360, Creo, or similar is fine. I need deliverables I can interpret in Fusion, so please provide STEP assemblies/parts and keep files well-structured with clear versioning. Native CAD files should also be provided.

Iteration Workflow:

I can 3D print locally for early iterations. Expect frequent revisions based on test feedback, especially around fit, wear points, looseness/rattle, and failure modes. I value clear communication, fast iteration, and disciplined file/version management.

Confidentiality + IP (Required):

I’m not attaching detailed CAD at this stage for confidentiality. Before any detailed file sharing, you must agree to:

NDA / strict confidentiality

Work-for-hire + IP assignment

No-portfolio / no public sharing (cannot post, reference, or discuss the work)

Time / Cadence:

Prefer someone available 10–20 hours/week, with 1–2 scheduled calls/week and async updates between calls. Ready to start ASAP; expect continuous iteration for several weeks/months depending on testing outcomes.

Please Reply With (Required):

1.) What failure modes would you design against for a repeatedly-used modular interface (wear, micro-slip, loosening, creep/preload loss, tolerance drift, debris/contamination, etc.) and how would you mitigate them?

2.) What materials/manufacturing assumptions would you make initially, and what would you research/verify about premium paddle construction before committing to a mechanism direction?

3.) How you choose clearances/tolerances for early 3D-printed prototypes vs later manufacturing so parts assemble reliably and remain consistent in production.

4.) Hourly rate, typical hours/week you can commit, and ability to do 1–2 scheduled calls/week plus async updates. read less