Senior/Principal Mechanical Design EngineerWe are unable to sponsor or take over sponsorship of an employment visa at this timeWe are seeking a highly experienced
Sr/Principal Mechanical Design Engineer to lead the mechanical design and scale-up of complex robotic modules from initial development through high-volume production.
This role will focus on the
end-to-end mechanical design of robotic systems, with an emphasis on developing products that can be reliably manufactured and scaled in a high-volume environment. The ideal candidate has deep experience designing highly complex electromechanical products and a strong understanding of high-volume manufacturing processes, including injection molding, thick-wall molding, die casting, and other metal molding/forming processes.
The successful candidate will work cross-functionally with engineering, manufacturing, operations, quality, and suppliers to take sophisticated robotic hardware from concept and design through production ramp and full-scale manufacturing.
Key Responsibilities- Lead the end-to-end mechanical design and scale-up of robotic modules from concept through high-volume production.
- Develop full-scale mechanical architectures and detailed designs for highly complex electromechanical robotic products.
- Design components, assemblies, and mechanisms with consideration for performance, reliability, manufacturability, cost, and high-volume production.
- Apply Design for Manufacturing (DFM) and Design for Assembly (DFA) principles throughout the product lifecycle.
- Develop designs utilizing high-volume manufacturing processes, including:
- Injection molding
- Thick-wall molding
- Die casting
- Metal molding and forming processes
- Machining and other precision manufacturing processes
- Partner with manufacturing engineers and suppliers to develop and validate tooling, production processes, and manufacturing specifications.
- Drive mechanical design decisions required to transition complex robotic modules from prototype builds into full-scale, high-volume production.
- Perform and/or support tolerance analysis, GD&T, material selection, structural analysis, and design validation.
- Identify design limitations and manufacturing risks early and develop solutions that enable reliable production at scale.
- Work closely with electrical, controls, systems, manufacturing, and other engineering disciplines to develop integrated electromechanical systems.
- Troubleshoot mechanical and manufacturing issues during development, production ramp, and sustaining engineering.
- Lead design reviews and provide technical direction on complex mechanical design challenges.
- Drive engineering changes and continuous design improvements based on testing, manufacturing feedback, quality data, and field performance.
- Collaborate with external suppliers and manufacturing partners to ensure designs meet quality, cost, and production requirements.
- Establish scalable mechanical design practices and standards that can be leveraged across future robotic products.
Required Qualifications- Bachelor's or Master's degree in Mechanical Engineering, Mechatronics, or a related engineering discipline.
- 10+ years of experience in mechanical design, product development, or a related engineering discipline; significantly more experience may be appropriate for Principal-level candidates.
- Proven experience scaling highly complex products from development through high-volume production.
- Strong experience designing complex electromechanical systems and assemblies.
- Demonstrated experience taking ownership of mechanical design at the module or system level, rather than exclusively designing individual components.
- Deep understanding of Design for Manufacturing (DFM) and Design for Assembly (DFA).
- Hands-on experience designing products for high-volume manufacturing.
- Strong experience with one or more of the following manufacturing processes:
- Injection molding
- Thick-wall molding
- Die casting
- High-volume metal molding/forming
- Precision machining
- Strong understanding of mechanical tolerances, GD&T, materials, fasteners, mechanisms, and structural design.
- Experience working directly with manufacturing teams, tooling engineers, and suppliers.
- Ability to solve complex mechanical design and manufacturing problems in a fast-paced product development environment.
Preferred Qualifications- Experience designing and scaling robotic systems, robotic modules, automation equipment, or other complex electromechanical products.
- Experience taking products through multiple stages of manufacturing scale-up, from prototype builds to pilot production and high-volume manufacturing.
- Experience with high-volume consumer electronics, automotive, aerospace, industrial automation, warehouse robotics, or similarly complex hardware.
- Experience with complex molded and cast metal components.
- Experience with injection mold and die-cast tooling development.
- Experience with tolerance stack-ups and designing assemblies for automated or high-volume assembly.
- Experience working with contract manufacturers and international suppliers.
- Strong CAD experience with a major mechanical design platform.
- Demonstrated ability to provide technical leadership on ambiguous and highly complex mechanical engineering problems.
