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OpenAIOpenAISan Francisco, CA

Actuator Electromagnetic Design Engineer

Leads architecture, electromagnetic design, integration, and validation of custom robotic actuators from concept through production readiness. The role requires 5+ years of relevant hardware experience, strong electromechanical systems knowledge, and hands-on prototyping and testing.

266k – 380k/yr
On-site5+ YOEHardware Engineering

About the role

Responsibilities

  • Lead the architecture, design, and integration of custom robotic actuators, including custom electromagnetic components.
  • Define actuator requirements and system-level trade studies covering torque density, bandwidth, efficiency, thermal performance, inertia, reliability, manufacturability, and cost.
  • Design precision electromechanical assemblies with attention to tolerances, alignment, load paths, thermal expansion, sealing, wear, and serviceability.
  • Drive actuator integration into robotic systems in partnership with controls, firmware, electrical, and robotics software teams.
  • Develop architectures with integrated sensing and encoder strategies.
  • Build and validate prototypes through hands-on bring-up, debugging, characterization, and iterative refinement.
  • Develop test methodologies and characterization infrastructure for performance, reliability, durability, and failure analysis.
  • Analyze test data to identify limitations, failure modes, and design improvements.
  • Collaborate with manufacturing and suppliers to transition prototypes to scalable production assemblies.
  • Support DFM, DFA, DFT, calibration, and assembly strategies for electromechanical subsystems.
  • Contribute to actuator sourcing, vendor qualification, prototype builds, and supply-chain development.
  • Document designs, interfaces, validation results, and engineering decisions.
  • Establish engineering standards, integration practices, and development workflows for robotic platforms.

Requirements

  • Bachelor's or graduate degree in Electrical Engineering, Robotics, Mechatronics, or a related field.
  • 5+ years of experience designing electromagnetic systems, robotic actuators, or precision mechatronic hardware.
  • Experience developing actuators for robotics, automation, aerospace, automotive, or other high-performance dynamic systems.
  • Strong understanding of motors, transmissions, bearings, encoders, structural design, thermal management, and precision mechanical integration.
  • Familiarity with actuator sensing architectures, encoder integration, and calibration strategies.
  • Experience designing for prototype and production processes, including machining, casting, molding, and assembly.
  • Proficiency with CAD and PLM tools such as NX and Teamcenter or equivalent systems.
  • Experience developing validation plans, reliability testing, and failure-analysis workflows.

Nice to Have

  • Experience scaling hardware from prototype through EVT, DVT, and PVT into production.

Compensation

  • Annual salary range: $266,000–$380,000.

Skills

electromagnetic systemsrobotic actuatorselectric motorstransmissionsbearingsencodersthermal managementCADNxteamcenterreliability testingfailure analysisDFMdfaplm

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