Mechanical Design Engineer

physicalintelligence; San Francisco (CA); On-site; USD 120,000 - 180,000; Full time

Job summary

physicalintelligence is seeking an experienced mechanical engineer to drive the integration and development of robotic systems from concept to deployment.

You will own the full spectrum of mechanical development, including actuator sizing, kinematics, prototyping, and mass‑production readiness, collaborating with electrical and radio teams to balance performance and reliability.

Qualifications

• Bachelor's degree in mechanical or aerospace engineering.
• 7+ years shipping mechanical designs for robotics or related fields.
• Deep understanding of high-volume manufacturing processes.
• Experience integrating electronics into complex assemblies.
• Hands-on, startup-friendly and fast-moving environment.

Responsibilities

• Own the mechanical design lifecycle: 3D CAD, 2D drawings, material selection, manufacturability from concept to production.
• Develop and refine manufacturing processes for injection molding, die casting, stamping, machining, bonding.
• Ensure reliability: HALT/HASS tests, tolerance analysis, environmental testing, corrective actions.
• Leverage basic FEA tools to guide design decisions from early phases onward.
• Lead system integration with electrical and radio teams for thermal and EMI balance.
• Prototype and iterate: build PoC designs, run experiments, translate findings to mass production.
• Manage vendor relationships: evaluate DFM, cost, yield, and timelines; collaborate with JDM/CM/ODM partners.
• Communicate design rationale and risks clearly through design reviews.

Skills

Mechanical design

Mechatronics

Cross-functional collaboration

Prototype development

Design reviews

Education

Bachelor's Degree in Mechanical or Aerospace Engineering

Tools

3D CAD

FEM/FEA tools

2D drafting

Job description

We're looking for an experienced mechanical engineer to drive the integration and development of our robotic systems, leading innovative designs from concept to deployment. You'll own the full spectrum of mechanical development—from actuator sizing or design to kinematics and work with teams to prototype and ultimately produce systems at scale—ensuring reliability, deployability, and performance. The ideal candidate is a hands‑on innovator with deep expertise in mechatronic systems, combining theoretical knowledge with practical engineering skills. Experience with actuation systems, electromechanical integration, machine design, and a track record of bringing mechanical systems to life is essential. If this sounds like you, please apply!

In This Role You Will

• Own the mechanical design lifecycle: Drive all design decisions around 3D CAD, 2D drawings, material selection, and manufacturability — from early concept and proof‑of‑concept prototypes through high‑volume production.
• Develop and refine manufacturing processes: Identify and optimize injection molding, die casting, stamping, machining, adhesives, and bonding methods for new and existing products.
• Ensure reliability and robustness: Perform and interpret reliability tests (HALT/HASS, tolerance stack‑ups, environmental testing) and lead corrective design actions.
• Leverage simulation for smart decisions: Use basic FEA tools (thermal, structural, vibrational) and first‑order analyses to validate or guide design from early phases onward.
• Lead system integration efforts: Collaborate with electrical and radio teams to balance thermal, EMI, mechanical stability, and accessibility needs in tightly integrated assemblies.
• Prototype and iterate quickly: Build proof‑of‑concept designs, run experiments, and translate findings into high‑yield, mass‑production‑ready solutions.
• Manage vendor relationships: Evaluate DFM, cost, yield, and timeline trade‑offs; work with JDM/CM/ODM partners; own and drive supplier selection where needed.
• Communicate effectively across teams: Conduct design reviews with cross‑functional stakeholders, clearly articulating design rationale, risks, and trade‑offs.

What We Hope You’ll Bring

• 7+ years of experience taking hardware products from concept to production, with a strong portfolio of shipped mechanical designs — preferably in robotics, automotive, or consumer products
• 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 for robust mechanical design
• Practical understanding of when and how to apply FEA tools, with the ability to make first‑order engineering judgments
• 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 with a willingness to move quickly and hands‑on
• 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

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