Senior​/Principal Mechanical Design Engineer

We are unable to sponsor or take over sponsorship of an employment visa at this time

We 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.

• 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.

• 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.

• 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…