Senior Mechanical Design Engineer

Role Outline

We are looking for a Mechanical Engineer to join a small, highly skilled team building advanced humanoid robotic platforms capable of dynamic, real-world operation. You will design and integrate complex mechanical subsystems - including actuation, structural frames, transmission systems, and thermal solutions. The ideal candidate thrives in fast-paced hardware development environments and has demonstrated success delivering high-performance electromechanical systems from prototype to scalable production.

Main Responsibilities

• Design and develop mechanical components and subsystems for humanoid robots, including structural frames, precision joints, and actuator assemblies, using advanced CAD tools and rigorous GD&T practices.
• Engineer high-performance robotic linkages and transmission mechanisms optimized for dynamic motion, load handling, durability, and energy efficiency.
• Select materials and manufacturing processes that balance strength, weight, cost, and scalability to ensure both prototype feasibility and production readiness.
• Collaborate with in-house manufacturing team for rapid prototyping efforts using additive manufacturing, CNC machining, and iterative hardware testing to validate and refine designs.
• Collaborate closely with electrical and software engineering teams to integrate mechanical systems with sensing, control, and embedded hardware architectures.
• Conduct mechanical analysis and validation testing (e.g., FEA, fatigue, impact, and life-cycle testing) to verify performance under real-world operating conditions.
• Drive safety-by-design principles, performing risk assessments and implementing safeguards to meet applicable regulatory and operational safety standards.
• Generate and maintain detailed engineering documentation, including production drawings, tolerance analyses, specifications, and bills of materials.
• Contribute to system-level design reviews and cross-functional execution to ensure on-time, high-quality hardware delivery.

Challenges

• Balancing Performance vs. Constraints: Managing trade-offs between strength, low weight, energy efficiency, reliability, and thermal management in a compact form factor, including designing custom high-precision actuation systems.
• Cross-Functional Integration and Interfacing: Ensuring seamless, rigorous integration of complex mechanical, electrical, and software subsystems, optimizing for cabling, sensors, and motor control.
• Scalability and Production Transition: Moving designs rapidly from custom prototypes to a robust, cost-effective, and scalable manufacturing process to support volume production growth.
• Fast-Paced, Multi-Disciplinary Environment: Thriving in a lean, fast-moving company, requiring the ability to own projects end-to-end, rapidly iterate, and adapt to evolving processes and tight deadlines.
• Adherence to Safety and Regulatory Standards: Implementing robust risk assessments and built-in safeguards from the initial design phase to ensure dynamic robotic systems meet international safety standards.

Qualifications, Knowledge, Key Skills and Experience

Essential

• Strong background in mechanical design, statics, dynamics, and material science.
• Advanced proficiency in 3D parametric CAD (preferably Autodesk Inventor).
• Deep understanding of GD&T and tolerance stack-up analysis.
• Strong background in mechanism design, linkages, bearings, power transmission, and actuator integration.
• Experience performing FEA and structural validation for dynamic loading conditions.
• Hands-on prototyping experience.
• Knowledge of material selection for lightweight, high-strength structures (aluminum alloys, steels, composites).
• Experience designing for manufacturability (DFM) and assembly (DFA).
• Ability to work cross-functionally with electrical and controls teams to integrate motors, sensors, wiring, and embedded systems.
• Proven ability to take hardware from concept through validation and into production.

Desirable

• Direct experience developing legged or humanoid robotic systems.
• Experience designing custom actuators, gear trains (harmonic drives, cycloidal reducers, planetary systems), or high-precision joints.
• Knowledge of thermal management for compact electromechanical assemblies.
• Familiarity with motion control systems and basic control theory.
• Understanding of safety standards for robotic systems.
• Startup experience or experience in fast-paced hardware development environments.
• Experience transitioning from prototype to volume manufacturing.

• Experience with mesh organic mesh modelling (Blender, Z-Brush).