Senior Mechanical Engineer

Position Overview

Bots Unlimited is a San Antonio-based product development and hardware company that designs, produces, and supports high performance technology for drones, robotics, automation, and edge AI systems. We operate in a fast‑moving, execution‑focused environment where team members own their work end to end and are trusted to manage themselves with a high level of accountability. This hands‑on, on‑site role will lead mechanical design, documentation, and manufacturability for our brushless DC motors, motor housings, rotors, stators, and other rotating/electromechanical assemblies.

You will directly enable our drone, robotics, and mobility products, turning prototype motor designs into production‑ready hardware that meets tight tolerance, material, and performance requirements.

• Develop 3D CAD models and detailed mechanical assemblies for motors, housings, rotor/stator sub‑assemblies, shafts, bearings, and related components.
• Produce full mechanical drawings: dimensioned parts, GD&T, tolerance stacks, material specifications, surface‑finish and plating/coating details.
• Manage and maintain mechanical data and revision control in our PLM system (e.g., Duro or equivalent).
• Create manufacturing‑ready documentation (BOMs, vendor quotes, machining/assembly work instructions, QC/inspection checklists).
• Perform DFM/DFMA reviews to ensure designs are optimized for cost, manufacturability, and reliability.
• Collaborate with electrical/firmware teams to ensure mechanical design supports motor performance, thermal requirements, and integration with ESC/housing.
• Interface with vendors and manufacturing partners: issue RFQs, review vendor drawings, negotiate tolerances, and coordinate prototype builds.
• Lead mechanical validation testing: oversee prototypes, manage assembly/disassembly, coordinate with test lab, and record physical test data (vibration, torque, RPM, thermal).
• Support product release: ensure all mechanical deliverables are complete for first‑article inspection, pre‑production, and mass production handoff.
• Mentor or guide less‑senior mechanical/design engineers where applicable.

• Bachelor’s or Master’s degree in Mechanical Engineering, Mechanical Design, or equivalent engineering discipline.
• Minimum 5–10 years of mechanical design experience, with substantial time spent designing rotating equipment, motors, or mechanical powertrain components.
• Expert proficiency in 3D CAD software (e.g., Solid Works, Autodesk Inventor, Creo) — able to create complex assemblies and prepare detailed 2D drawings with GD&T.
• Solid understanding of GD&T, tolerance analysis, material properties, surface finish, coatings/plating, fasteners, and mechanical fit/clearance principles.
• Proficiency in using standard mechanical engineering tools and instruments such as calipers, micrometers, gauges, dial indicators, and other measurement or inspection tools required for prototype validation, fit/clearance checks, and vendor QA collaboration.
• Experience with PLM or PDM systems (e.g., Duro, Windchill, Arena) to manage part revisions, BOMs, and release workflows.
• Familiarity with manufacturing processes: CNC machining, sheet‑metal, casting, magnet assembly/stacking, rotor balancing, assembly tolerances, vendor sourcing.
• Strong documentation skills: ability to draft manufacturing instructions, inspection checklists, QC requirements, and vendor drawing packages.
• Experience working with or specifying bearings, shafts, rotor‑stator assemblies, magnets, housings, and mechanical/magnetic tolerances relevant for motor design.
• Ability to collaborate with multidisciplinary teams (electrical, firmware, mechanical, quality) and vendors to drive designs through to production.
• Excellent communication skills (written and verbal), and ability to work onsite in San Antonio — vendor visits and hands‑on builds expected.
• Travel: willingness to travel periodically throughout the year to support key product milestones and collaboration efforts.

• Prior experience designing or supporting brushless DC motors, electric motors, or electromechanical actuators / gear‑driven mechanisms.
• Experience…