# Senior Design Engineer

**Company:** [GrayMatter Robotics](https://hotfix.jobs/companies/graymatter-robotics)
**Location:** Carson, CA
**Role:** Hardware Engineering
**Salary:** $135k – $250k/yr
**Experience:** 8+ years
**Skills:** Solidworks, CAD, FEA, GD&T, DFM, Dfa, Tolerance Analysis, Cnc Machining, 3D Printing, Root Cause Analysis, Mechanical Design, Robotic Hardware
**Posted:** 2026-07-14

> 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.

## Job Description

## 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.

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