Senior Mechanical Engineer - Structural Simulation & Analysis

jobs.frontdoordefense.com - Jobboard; Austin (TX); On-site; USD 90,000 - 120,000; Full time

Job summary

Apptronik is looking for a Senior Mechanical Engineer – Structural Simulation in Austin, TX, to optimize the design and reliability of our humanoid robot, Apollo. You will perform critical simulations, guide design standards, and work on non-linear dynamic analysis, while mentoring junior engineers and collaborating with test teams.

Candidates should possess a degree in Mechanical or Aerospace Engineering, coupled with 4+ years of experience in structural simulation—all aimed at driving innovative robotics solutions.

Qualifications

• 4+ years of experience in structural simulation and mechanical design.
• Proven track record in high-performance electromechanical products.
• Experience with high-speed moving mechanisms preferred.

Responsibilities

• Guide the culture from design and then check to simulation-driven design.
• Support development of standards for material models and safety factors.
• Perform analysis of complex, non-linear events during rapid limb acceleration.
• Utilize topology optimization for aggressive mass reduction.
• Design physical experiments to validate simulation models.
• Lead characterization of specialized materials for accurate simulation.
• Mentor junior engineers and provide deep-dive design reviews.

Skills

Structural simulation

Mechanical design

Ansys

Abaqus

Computational Mechanics

Durability analysis

Education

B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or related field

Tools

Simulation suites

Job description

Senior Mechanical Engineer – Structural Simulation & Analysis

Lead simulation-driven design efforts to optimize Apollo’s structural performance and reliability

Location: Austin

Job Tags: Hardware

About The Role

Austin, TX

Apptronik is a human-centered robotics company developing AI-powered robots to support humanity in every facet of life. Our flagship humanoid robot, Apollo, is built to collaborate thoughtfully with people, starting with critical industries such as manufacturing and logistics, with future applications in healthcare, the home, and beyond. We operate at the cutting edge of embodied AI, applying our expertise across the full robotics stack to solve some of society's most important problems. You will join a team dedicated to bringing Apollo to market at scale, tackling the complex challenges like safety, commercialization, and mass production to change the world for the better.

Job Summary: Apptronik is seeking a Senior Mechanical Engineer – Structural Simulation to serve as part of the technical team responsible for the structural integrity, mass optimization, and dynamic performance of our humanoid robot, Apollo. In this role, you will perform simulations that allow us to move from ‘concept’ to ‘validated hardware’ with minimal physical prototyping cycles. As a senior engineer, you will tackle the most complex physics problems such as impact dynamics, high-cycle fatigue in high-DOF joints, and multi-body dynamics, ensuring that every gram of material on the robot is earning its keep. You will bridge the gap between high-level autonomous behaviors and the physical limits of the machine’s skeleton.

Essential Duties and Responsibilities or Key Accountabilities:

• Predictive Engineering: Help guide the culture from ‘design and then check’ to ‘simulation-driven design’ where analysis informs the initial architectural trade-offs of the robot.
• Standardization: Support the development of company-wide standards for material models, boundary conditions, and safety factors for humanoid-specific load cases (e.g., falls, high-speed walking, and heavy lifting).
• Non-Linear & Dynamic FEA: Perform analysis of complex, non-linear events such as high-velocity impacts (robot falls) and transient dynamic loads during rapid limb acceleration.
• Fatigue & Life Prediction: Perform fatigue life models for the robot’s primary structure. Predict the lifecycle of components subjected to millions of gait cycles using advanced fracture mechanics and durability analysis.
• Mass Optimization: Utilize topology optimization and generative design to drive aggressive mass reduction across the limbs and torso while maintaining required stiffness-to-weight ratios.
• Test/Sim Correlation: Work closely with the Hardware Integration and Test team to design physical experiments (strain gauging, modal testing, drop tests) that validate and ‘tune’ your simulation models.
• Material Characterization: Lead the efforts to characterize specialized materials—from high-strength aerospace alloys to advanced composites and 3D‑printed lattices—to ensure accurate simulation inputs.
• Mentorship: Act as a technical mentor for junior engineers, providing ‘deep-dive’ design reviews and solving the ‘impossible’ physics bottlenecks.

Skills and Requirements

Education: B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or a related field with a focus on Computational Mechanics.

Experience: 4+ years of experience in structural simulation and mechanical design, with a proven track record of shipping complex, high-performance electromechanical products (Robotics, Aerospace, or Automotive). Software Mastery: Proficiency in industry-standard simulation suites (e.g., Ansys, Abaqus, SimCenter). Physics Depth: Solid mechanics, vibration (vibration, shock, and modal analysis), heat transfer, and multi-body dynamics. Humanoid Context: Specific experience with high-speed moving mechanisms or ‘lightweighting’ structures for mobile platforms is highly preferred.

Physical Requirements: Prolonged periods of sitting at a desk and working on a computer. Must be able to lift 15 pounds at times. Vision to read printed materials and a computer screen. Hearing and speech to communicate.

This is a direct hire. Please, no outside Agency solicitations.

Apptronik provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.