Senior Design Engineer
Design and optimize robotic hardware, mechanisms, and End-of-Arm Tooling for GrayMatter Robotics' Physical AI systems. Requires 8+ years of mechanical design experience with CAD, FEA, DFM, and manufacturing processes; BS/MS in Mechanical Engineering.
About the job
Robotic Hardware Design
- Design hardware and mechanisms for robotic systems, including system architectures.
- Develop and review new concepts with a primary focus on performance and reliability.
EOAT Design & DFM Compliance
- Collaborate with cross-functional teams to drive product improvements focusing on Design for Manufacturing (DFM) for End-of-Arm Tooling (EOAT).
- Ensure compliance with ISO/TR 20218-1 safety guidelines.
Advanced FEA & Simulation
- Conduct complex Finite Element Analysis (FEA) and thermal simulations to validate structural integrity, predict failure modes, and optimize geometry before fabrication.
Structural Analysis
- Perform foundational structural analysis and simulation to validate design integrity.
Rapid Prototyping
- Prototype hardware considering Design for Manufacturability (DFM), utilizing tools such as 3D printers and CNC machines where appropriate.
Hardware Selection
- Own the selection process for distinct electrical, mechanical, and pneumatic hardware components.
System Integration
- Collaborate closely with Electrical and Software teams to ensure seamless integration of motors, sensors, and cabling within the mechanical assembly.
System Troubleshooting & Optimization
- Troubleshoot and test existing hardware and automation systems to identify opportunities for robustness and significant improvements.
Root Cause Analysis
- Lead formal root cause investigations (e.g., 8D, Fishbone, 5 Whys) for field failures or manufacturing defects to implement permanent corrective actions.
Safety Compliance & Risk Assessment
- Lead mechanical risk assessments (RA) and ensure system designs adhere to core industrial safety standards, including ISO 10218-1/-2 and ANSI/A3 R15.06.
Design and Tolerance
- Effectively implement GD&T (Geometric Dimensioning and Tolerancing), Tolerance Analysis, Design for Manufacturing, Design for Assembly.
Collaboration
- Collaborate cross-functionally with internal and external teams to define customer requirements, validate project feasibility, and coordinate material procurement for in-house testing prior to deployment.
BOM & Inventory Management
- Organize part number allocation and review Bills of Materials (BOMs) for completeness to actively support inventory management and system deployment as well as maintaining an accurate BOM in PDM.
Cost Reduction Initiatives
- Execute Value Analysis/Value Engineering (VAVE) efforts to reduce Bill of Materials (BOM) costs without compromising system performance or reliability.
Vendor Technical Management
- Manage relationships with external machine shops and component suppliers to ensure part quality, lead time adherence, and cost-effectiveness.
Validation Strategy
- Make strategic recommendations for design validation and testing protocols.
Lifecycle Management
- Oversee the full mechanical product lifecycle from initial conceptualization through mass production and end-of-life support.
Mentorship
- Lead, mentor, and actively develop junior talent within the engineering team.
Minimum Qualifications
- BS/MS in Mechanical Engineering or equivalent experience.
- Demonstrated experience with 3D solid modeling, analysis, and development of 2D manufacturing drawings.
- Thorough understanding of manufacturing processes: manual machining, CNC machining, welding, sheet metal fabrication, plastic 3D prototyping.
- Thorough understanding of materials for manufacturing.
- 8+ years working proficiency with CAD programs, hands-on prototyping, fabrication or ability to design for 3D printing.
- Proven track record of strong communication skills and ability to collaborate effectively across multiple teams and customers.
- Willingness to work at early stage company with dynamic priorities.
- Ability to conduct RCCAs and trade studies.
- Ability to solve problems effectively in a collaborative environment.
Preferred Qualifications
- 8+ years working proficiency with SolidWorks.
- Experience with industrial robots and 6 DOF robotic arms.
- Experience machining, rapid prototyping and fabrication processes/materials to meet functional design requirements.
- Experience with project management.
- Experience with product deployment.
- Familiar with industrial facilities and equipment.
Skills
Solidworks, CAD, FEA, GD&T, DFM, Dfa, Tolerance Analysis, Cnc Machining, 3D Printing, Root Cause Analysis, Mechanical Design, Robotic Hardware
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