Mechanical Design Engineer, Body Structures, Frame (Autonomous Vehicle Team)

Foundation Robotics Labs Inc.; San Francisco (CA); On-site; USD 115,000 - 150,000; Full time

Benefits offered by this job

Health insurance

Vision insurance

Dental insurance

401k plan

Job summary

A cutting-edge robotics company based in San Francisco seeks an experienced engineer to design and develop vehicle structures for all-terrain use. With a focus on innovation and durability, the position requires hands-on experience in mechanical systems and proficiency in 3D CAD tools like SolidWorks. Candidates should be adept at FEA and fabrication processes. Competitive annual compensation ranges from $115,000 - $150,000, depending on experience and skills.

Qualifications

• 5+ years of hands-on experience designing and building structural mechanical systems.
• Strong proficiency in 3D CAD with disciplined approach.
• Experience using FEA and simulation tools to inform design decisions.
• Practical experience with fabrication processes like welding and machining.
• Solid understanding of materials and their structural applications.
• Experience designing for harsh environments including corrosion.
• Ability to think in systems and achieve design integration.

Responsibilities

• Design and develop the vehicle body for extreme conditions.
• Own structural performance from concept through prototype.
• Engineer frame systems optimizing stiffness-to-weight ratio.
• Drive rapid prototyping efforts translating CAD to builds.
• Design robust joints and interfaces for harsh environments.

Skills

Design and build structural mechanical systems

3D CAD proficiency (SolidWorks, CATIA, NX)

FEA and simulation tool experience (ANSYS, ADAMS)

Fabrication processes (welding, machining, sheet metal)

Understanding of materials' trade-offs

Design for harsh environments

Systems thinking in design integration

Tools

SolidWorks

CATIA

NX

ANSYS

ADAMS

Job description

About Foundation:

Foundation is developing the future of general purpose robotics and electric mobility with the goal to save lives and augment human labor.

Our mission is to create an autonomous, crewless ATV built to be truly all‑terrain. Designed for commercial and defense use, it can save lives and take on heavy transport across mining, agriculture, construction, and more.

We are on the lookout for extraordinary engineers and scientists to join our team. Your previous experience in robotics isn’t a prerequisite — it’s your talent and determination that truly count.

We expect that many of our team members will bring diverse perspectives from various industries and fields. We are looking for individuals with a proven record of exceptional ability and a history of creating things that work.

Why We Are Hiring for This Role:

• Design and develop the vehicle body and structural architecture to perform across extreme multi‑environment conditions—from high‑impact off‑road shock loads to full water submersion and long‑term vibration fatigue.
• Own structural performance from concept through prototype, using FEA and simulation‑driven design to rapidly iterate on geometries, reduce material usage, and accelerate development cycles.
• Engineer frame systems that achieve an optimized stiffness‑to‑weight ratio through thoughtful material selection across steel alloys, aluminum extrusions, and composite structures.
• Drive rapid prototyping efforts by translating CAD designs into physical builds using CNC machining, welding, sheet metal fabrication, and additive manufacturing.
• Design robust joints and interfaces that account for thermal expansion, corrosion between dissimilar metals, and long‑term serviceability in harsh environments.
• Collaborate closely with robotics, suspension, and systems engineering to co‑develop structural hardpoints, mounting interfaces, and routing pathways as part of a fully integrated vehicle architecture.

What Kind of Person We Are Looking For:

• 5+ years of hands‑on experience designing and building structural mechanical systems.
• Strong proficiency in 3D CAD (SolidWorks, CATIA, NX, or similar), with a disciplined approach to assemblies, tolerancing, and managing complex multi‑part systems.
• Experience using FEA and simulation tools (ANSYS, ADAMS, or similar) to inform design decisions, including structural, fatigue, and modal analysis.
• Practical experience with fabrication processes such as welding, machining, and sheet metal—comfortable working between CAD and the shop floor.
• Solid understanding of materials and their trade‑offs in structural applications, including strength, fatigue, corrosion resistance, and weight.
• Experience designing for harsh environments, including water exposure, corrosion, and sealing of structural systems.
• Ability to think in systems—designing structures that integrate cleanly with actuators, wiring, fluid systems, and sensors from the outset.

Benefits

• We provide market standard benefits (health, vision, dental, 401k, etc.). Join us for the culture and the mission, not for the benefits.

Salary

• The annual compensation is expected to be between $115,000 - $150,000+. Exact compensation may vary based on skills, experience, and location.