Mechanical Design Engineer

The role

This person will drive the integration and development of robotic systems from concept to deployment. They will own the full mechanical development spectrum including actuator sizing, kinematics, prototyping, and production at scale.

What you will do

• Drive design decisions around 3D CAD, 2D drawings, material selection, and manufacturability.
• Identify and optimize manufacturing processes like injection molding, die casting, stamping, machining, adhesives, and bonding.
• Perform and interpret reliability tests including HALT/HASS, tolerance stack-ups, and environmental testing.
• Use basic FEA tools and first-order analyses to validate or guide design.
• Collaborate with electrical and radio teams to balance thermal, EMI, mechanical stability, and accessibility needs.
• Build proof-of-concept designs, run experiments, and translate findings into mass-production-ready solutions.
• Evaluate DFM, cost, yield, and timeline trade-offs with JDM/CM/ODM partners.
• Conduct design reviews with cross-functional stakeholders.

Required qualifications

• 7+ years of experience taking hardware products from concept to production
• Bachelor's Degree in Mechanical or Aerospace Engineering, or equivalent experience
• Deep understanding of high-volume manufacturing processes (injection molding, die casting, stamping, machining, bonding)
• Familiarity with HALT/HASS, FMEA, DOE methodologies, and test-to-failure approaches
• Practical understanding of when and how to apply FEA tools
• Proven record of mechanically integrating electronics (sensors, PCBs, antennas, batteries) in complex assemblies
• Ability to lead reviews, influence cross-functional teams, and convey risks and solutions clearly
• Comfort in early-stage, resource-limited startup environments
• Proficiency in prototyping methods including machining (mill, lathe), sheet metal fabrication, 3D printing, and injection molding
• Experience building and testing prototypes and analyzing failures to implement improvements

Nice to have

• preferably in robotics, automotive, or consumer products

Before you apply

• Pursuant to the San Francisco Fair Chance Ordinance, we will consider for employment qualified applicants with arrest and conviction records.

About the company

physicalintelligence is looking for an experienced mechanical engineer to drive the integration and development of robotic systems.