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

Hardware FYI; San Francisco, Northern (CA, KY); Hybrid; USD 150,000 - 250,000; Full time

Benefits offered by this job

Market standard benefits

Equity

Job summary

Foundation is seeking a senior structural mechanical engineer to design the vehicle body and architecture for extreme multi-environment conditions. You will drive prototyping and ensure integration with robotics and systems engineering for a cohesive vehicle platform.

We value 5+ years of hands-on experience, proficiency in 3D CAD and FEA, and practical fabrication knowledge. The role emphasizes rugged design, material trade-offs, and durable interfaces for demanding environments.

Qualifications

• 5+ years designing and building structural mechanical systems.
• Proficient in 3D CAD with disciplined assemblies and tolerancing.
• Experience with FEA and simulation for structural analyses.
• Fabrication experience including welding and machining.
• Strong materials knowledge for structural applications.
• Ability to design for harsh environments and corrosion resistance.

Responsibilities

• Design and develop the vehicle body and structural architecture for multi-environment use.
• Own structural performance from concept through prototype with iterative design.
• Engineer frame systems with optimized stiffness-to-weight ratio.
• Drive rapid prototyping via CAD-to-build workflows (CNC, welding, sheet metal, additive).
• Design robust joints accounting for thermal expansion, corrosion, and serviceability.
• Collaborate with robotics, suspension, and systems engineering on integration.

Skills

Structural mechanical design

3D CAD

FEA & simulation

Fabrication knowledge

Materials science

Rugged environment design

Systems thinking

Tools

SolidWorks

CATIA

NX

ANSYS

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:

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.), equity. Join us for the culture and the mission, not for the benefits.

Salary

• The annual compensation is expected to be between $150,000 - $250,000. Exact compensation may vary based on skills, experience, and location.