Robotics Mechanical Design Lead for High-Volume Scale-Up

Kaleidoscope Innovation, Inc.; Boston (MA); Hybrid; USD 100,000 - 200,000; Full time

Job summary

Kaleidoscope Innovation, Inc. in Boston, MA, is seeking a Senior/Principal Mechanical Design Engineer to lead the mechanical design and scale-up of robotic modules from development through high-volume production.

The role focuses on end-to-end mechanical design of robotic systems with emphasis on manufacturability and scalable processes. The ideal candidate has deep experience in electromechanical products, DFM/DFA, and high-volume manufacturing methods such as injection molding, thick-wall

Qualifications

• Bachelor's or Master's in Mechanical Engineering, Mechatronics, or a related engineering discipline.
• 10+ years in mechanical design or related engineering discipline; significantly more may be appropriate for Principal-level candidates.
• Proven experience scaling highly complex products from development through high-volume production.
• Deep understanding of Design for Manufacturing (DFM) and Design for Assembly (DFA).

Responsibilities

• Lead end-to-end mechanical design and scale-up of robotic modules from concept through high-volume production.
• Develop full-scale mechanical architectures and detailed designs for highly complex electromechanical robotic products.
• Design components, assemblies, and mechanisms with consideration for performance, reliability, manufacturability, cost, and high-volume production.
• Apply Design for Manufacturing (DFM) and Design for Assembly (DFA) principles throughout the product lifecycle.
• Thick-wall molding, metal molding and forming processes, machining and other precision manufacturing processes.
• Partner with manufacturing engineers and suppliers to develop and validate tooling, production processes, and manufacturing specifications.
• Drive mechanical design decisions required to transition complex robotic modules from prototype builds into full-scale, high-volume production.
• Perform tolerance analysis, GD&T, material selection, structural analysis, and design validation.
• Identify design limitations and manufacturing risks early and develop solutions that enable reliable production at scale.
• Work closely with electrical, controls, systems, manufacturing, and other engineering disciplines to develop integrated electromechanical systems.
• Troubleshoot mechanical and manufacturing issues during development, production ramp, and sustaining engineering.
• Lead design reviews and provide technical direction on complex mechanical design challenges.
• Drive engineering changes and continuous design improvements based on testing, manufacturing feedback, quality data, and field performance.
• Collaborate with external suppliers and manufacturing partners to ensure designs meet quality, cost, and production requirements.
• Establish scalable mechanical design practices and standards that can be leveraged across future robotic products.

Skills

10+ years experience

Electromechanical design

DFM/ DFA

High-volume manufacturing

CAD software

Education

Bachelor's or Master's in Mechanical Engineering

Tools

CAD software

Job description

Kaleidoscope Innovation, Inc. in Boston, MA, is seeking a Senior/Principal Mechanical Design Engineer to lead the mechanical design and scale-up of robotic modules from development through high-volume production.

The role focuses on end-to-end mechanical design of robotic systems with emphasis on manufacturability and scalable processes. The ideal candidate has deep experience in electromechanical products, DFM/DFA, and high-volume manufacturing methods such as injection molding, thick-wall