Mechanical Lead – Robotics and Industrial Systems

Role Summary:

As the Mechanical Lead, you will be responsible for the design, development, and optimization of mechanical systems for robotic applications. You will oversee the Mechanical Engineering team and work closely with cross-functional teams, including Robotics, Embedded Systems, and Edge AI, to integrate mechanical solutions seamlessly with software and electronics. This role requires a strong foundation in mechanical engineering, hands-on experience with prototyping, and the ability to lead a team in developing innovative solutions for advanced robotic platforms.

Core Responsibilities:

• Mechanical System Design and Development Lead End-to-End Mechanical Design: Oversee the entire mechanical design process, from concept through to final prototype. This includes selecting materials, defining design specifications, and creating CAD models to meet performance requirements. Design for Robustness and Durability: Focus on designing robotic systems that are robust, reliable, and durable for demanding industrial environments. Ensure that designs meet or exceed requirements for operating in extreme conditions, including temperature, moisture, and physical impact.
• Multi-Degree-of-Freedom Systems: Design and develop multi-DOF robotic structures, including actuators, linkages, and mechanisms for complex movements. Address the unique challenges of quadrupeds, humanoids, and bionic robots that require precise control and stability in various operational scenarios. Structural Analysis and Optimization • Finite Element Analysis (FEA): Conduct FEA to validate design robustness, optimize load-bearing capabilities, and reduce weight without compromising structural integrity. Use simulation tools to predict potential points of failure and refine designs accordingly. • Motion Analysis and Kinematics: Perform kinematic and dynamic analyses to ensure that the robotic structures can achieve the desired range of motion, speed, and control. Work closely with software teams to validate that mechanical design aligns with control algorithms for smooth and accurate movement. • Thermal and Stress Management: Design solutions that address thermal and stress-related challenges, ensuring that components maintain performance under heavy usage. Implement passive and active cooling mechanisms as necessary, especially for applications with embedded electronics.
• Prototyping, Testing, and Iteration • Rapid Prototyping: Lead the team in building and testing prototypes to validate design concepts and make improvements. Leverage rapid prototyping methods such as 3D printing, CNC machining, and laser cutting to iterate quickly on designs. • Testing and Validation: Develop and oversee rigorous testing protocols to validate the performance, durability, and reliability of mechanical components. This includes stress testing, fatigue testing, and environmental testing to ensure compliance with quality and safety standards. • Continuous Improvement: Implement a feedback loop from testing to design, refining and iterating prototypes based on test outcomes. Optimize designs for manufacturability, assembly, and scalability, preparing them for mass production if needed.
• Collaboration with Cross-Functional Teams • Work Closely with Robotics and Software Teams: Collaborate with robotics and control engineers to ensure mechanical designs support the functional requirements of control systems and AI algorithms. Provide input on sensor placement, wiring pathways, and other considerations for seamless integration. • Coordinate with Edge AI and Embedded Systems: Work with the Edge AI and embedded systems teams to ensure compatibility between mechanical design and embedded hardware, especially in relation to actuator control, power management, and thermal constraints. • Manufacturing and Supply Chain Coordination: Collaborate with manufacturing, sourcing, and supply chain teams to ensure design feasibility for production. Evaluate material availability, cost, and manufacturing processes to optimize production scalability.
• Leadership and Team Management • Manage and Mentor the Mechanical Engineering Team: Lead a team of mechanical engineers, providing technical guidance, setting performance goals, and fostering a collaborative environment. Conduct regular performance reviews and support team members in their professional growth. • Project and Resource Management: Oversee project timelines, resource allocation, and task prioritization within the mechanical engineering team. Ensure alignment with overall project goals and coordinate with other departments to achieve timely project milestones. • Promote Innovation and Technical Excellence: Encourage team members to stay updated with the latest advancements in mechanical engineering, materials science, and robotics. Promote knowledge sharing and continuous improvement within the team.
• Innovation and R&D in Robotics Mechanical Engineering • Explore New Materials and Technologies: Stay informed on advancements in materials (e.g., composites, lightweight metals, 3D-printed materials) and evaluate their applicability in robotic design. Experiment with innovative materials to improve the performance, strength, and efficiency of robotic systems. • Lead R&D Projects: Initiate research projects focused on solving specific mechanical challenges in robotics, such as developing flexible or bio-inspired mechanisms for bionic robots. Oversee proof-of-concept projects that explore new designs and mechanical solutions. • Community and Industry Engagement: Represent the company in industry forums, conferences, and other events to stay connected with the latest trends in robotics and mechanical engineering. Encourage the team's involvement in open-source projects and knowledge sharing within the robotics community.
• Compliance, Safety, and Quality Assurance • Safety and Compliance Standards: Ensure that all designs and prototypes meet relevant safety standards and comply with industry regulations. Conduct risk assessments and implement design features that enhance safety and prevent potential hazards. • Quality Control and Documentation: Implement quality control processes for mechanical components, ensuring consistency and reliability in production. Maintain thorough documentation of designs, test results, and iteration history for reproducibility and compliance. • Continuous Quality Improvement: Develop and execute plans for continuous quality improvement. Analyze feedback from testing, manufacturing, and field use to make data-driven improvements to designs.

Required Qualifications:

• Education: Bachelor's or Master's degree in Mechanical Engineering, Robotics, or a related field. Advanced degrees or certifications in mechanical design, materials science, or robotics are preferred.
• Experience: • 10+ years of experience in mechanical engineering, with at least 5 years in a leadership role. • Proven experience designing and developing mechanical systems for robotics, industrial automation, or similar applications. • Strong track record in leading teams through the full product development lifecycle, from concept to production-ready designs.

Technical Skills:

• Mechanical Design and CAD: Proficiency in CAD software (e.g., SolidWorks, CATIA, Autodesk Inventor) for designing complex mechanical systems.
• Finite Element Analysis (FEA): Experience with FEA tools (e.g., ANSYS, Abaqus) for structural analysis, thermal management, and stress testing.
• Prototyping and Fabrication: Hands-on experience with prototyping tools and techniques, including 3D printing, CNC machining, and rapid fabrication methods.
• Kinematics and Dynamics: Strong knowledge of kinematics, dynamics, and control principles for multi-DOF robotic systems.
• Generative AI and Design: Experience with generative AI tools and generative design techniques for optimizing mechanical structures and creating innovative solutions. o Bionic Robot Development: Expertise in designing and developing bionic robots, including quadrupeds and humanoids, with a focus on biomimetic principles and advanced locomotion systems.
• Simulation and Modeling: Proficiency in using simulation tools (e.g., MATLAB/Simulink, ROS, Gazebo) for testing and validating robotic designs in virtual environments before physical prototyping.

Preferred Qualifications:

• Robotics and Automation Knowledge: Understanding of robotic control systems, actuation technologies, and sensor integration for autonomous systems.
• Industrial Standards and Compliance: Familiarity with industrial safety standards and regulatory requirements for manufacturing and automation.
• Project Management and Agile Methodologies: Experience in project management and Agile practices for managing timelines, resources, and cross-functional collaborations.
• Materials Science and Innovation: Knowledge of materials science, including advanced composites and lightweight metals, with experience selecting materials for strength, weight, and cost efficiency.