Mechanical Engineer, PCBA Test Infrastructure, Robotics

Mechanical Engineer, PCBA Test Infrastructure, Robotics | OpenAI

Careers

Robotics - San Francisco

Our Robotics team is focused on unlocking general-purpose robotics and pushing towards AGI-level intelligence in dynamic, real-world settings. Working across the entire model stack, we integrate cutting‑edge hardware and software to explore a broad range of robotic form factors. We strive to seamlessly blend high‑level AI capabilities with the constraints of physical systems to improve peoples’ lives.

We are seeking a Mechanical Engineer for a senior individual‑contributor role leading printed circuit board assembly (PCBA) test fixtures and infrastructure for advanced robotic systems. You will independently turn evolving requirements into working fixtures, make technical tradeoffs, and own delivery from concept and detailed design through fabrication, validation, deployment, and reliable operation.

This role combines development‑lab work with deployment at contract manufacturers. You will build precision mechanical systems for board programming, functional test, and characterization, including board nests, probe plates, connector interfaces, alignment features, clamps, enclosures, and thermal interfaces. You will partner with electrical, firmware, software, manufacturing, and reliability teams to make fixtures repeatable, protective of delicate assemblies, and maintainable as board designs evolve.

This role is based in San Francisco, CA, and requires in‑person presence 4 days a week. Travel to contract‑manufacturer sites is part of the role, with timing based on build and deployment needs.

• Own the mechanical architecture of PCBA test stations, including frames, board nests, datum schemes, access, guarding, ergonomics, and serviceability.

• Design probe and bed‑of‑nails fixtures, connector‑mating mechanisms, board supports, clamps, and interchangeable tooling for programming, functional test, and characterization.

• Use first‑principles analysis and simulation to assess stiffness, probe and insertion forces, board deflection, tolerance stacks, thermal growth, and fixture life; validate key predictions on hardware.

• Develop locating and compliance features that accommodate board and assembly variation, protect components and solder joints, and preserve contact repeatability across loading cycles and board revisions.

• Partner with electrical engineers on test‑point access, probe selection, connector engagement, ESD provisions, cable routing, cooling, and interlocks; define motion and sequencing constraints with software and controls partners.

• Build, assemble, instrument, and debug fixtures in the lab. Establish acceptance checks for alignment, force, board strain where needed, contact repeatability, and cycle life; separate fixture problems from board failures.

• Design safe loading, pinch‑point protection, hard stops, and operator access for manual or actuated fixtures. Make wear components easy to inspect, clean, and replace.

• Manage fabrication partners and component vendors. Release CAD, drawings, bills of materials, tolerance analyses, assembly instructions, inspection plans, and maintenance procedures.

• Own fixture deployment and acceptance at contract manufacturers, including assembly and alignment checks, correlation with lab fixtures, operator training, and troubleshooting. Support replication, board‑revision changes, and maintenance through released documentation.

• Have strong mechanical intuition for precision interfaces, load paths, compliance, tolerances, and the behavior of delicate electronic assemblies.

• Move readily between analysis, CAD, vendor…