Senior/Principal Mechanical Design Engineer

KALEIDOSCOPE Innovation; Boston (MA); On-site; USD 150,000 - 230,000; Full time

Job summary

Kaleidoscope Innovation in Boston is seeking a Sr/Principal Mechanical Design Engineer to lead the end-to-end mechanical design and scale-up of complex robotic modules from concept through high-volume production. The role requires deep experience with electromechanical systems and manufacturability to ensure reliable, scalable products.

You will partner with manufacturing, operations, quality, and suppliers to drive designs that meet performance, cost, and schedule targets while leveraging

Qualifications

• 10+ years in mechanical design or a related engineering discipline.
• Proven experience scaling complex products to high-volume production.
• Expertise in electromechanical systems and DFA/DFM practices.

Responsibilities

• Lead end-to-end mechanical design and scale-up of robotic modules to high-volume production.
• Develop full-scale architectures and detailed designs for complex electromechanical products.
• Ensure manufacturability, reliability, and cost targets across the product lifecycle.
• Apply DFM/ DFA, tolerance analysis, and GD&T during design and validation.
• Collaborate with manufacturing, suppliers, and other engineering teams to transition from prototype to production.

Skills

Mechanical design

Electromechanical systems

DFM/ DFA

GD&T

High-volume manufacturing

Project leadership

Vendor collaboration

Education

Mechanical Engineering degree

Tools

CAD software

FEM software

Job description

We are unable to sponsor or take over sponsorship of an employment visa at this time

We are seeking a highly experienced Sr/Principal Mechanical Design Engineer to lead the mechanical design and scale-up of complex robotic modules from initial development through high-volume production.

This role will focus on the end-to-end mechanical design of robotic systems, with an emphasis on developing products that can be reliably manufactured and scaled in a high-volume environment. The ideal candidate has deep experience designing highly complex electromechanical products and a strong understanding of high-volume manufacturing processes, including injection molding, thick-wall molding, die casting, and other metal molding/forming processes.

The successful candidate will work cross-functionally with engineering, manufacturing, operations, quality, and suppliers to take sophisticated robotic hardware from concept and design through production ramp and full-scale manufacturing.

Key Responsibilities

• Lead the 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.
• Develop designs utilizing high-volume manufacturing processes, including:
• Injection molding
• Thick-wall molding
• Die casting
• 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 and/or support 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.

Required Qualifications

• Bachelor's or Master's degree in Mechanical Engineering, Mechatronics, or a related engineering discipline.
• 10+ years of experience in mechanical design, product development, or a related engineering discipline; significantly more experience may be appropriate for Principal-level candidates.
• Proven experience scaling highly complex products from development through high-volume production.
• Strong experience designing complex electromechanical systems and assemblies.
• Demonstrated experience taking ownership of mechanical design at the module or system level, rather than exclusively designing individual components.
• Deep understanding of Design for Manufacturing (DFM) and Design for Assembly (DFA).
• Hands-on experience designing products for high-volume manufacturing.
• Strong experience with one or more of the following manufacturing processes:
• Injection molding
• Thick-wall molding
• Die casting
• High-volume metal molding/forming
• Precision machining
• Strong understanding of mechanical tolerances, GD&T, materials, fasteners, mechanisms, and structural design.
• Experience working directly with manufacturing teams, tooling engineers, and suppliers.
• Ability to solve complex mechanical design and manufacturing problems in a fast-paced product development environment.

Preferred Qualifications

• Experience designing and scaling robotic systems, robotic modules, automation equipment, or other complex electromechanical products.
• Experience taking products through multiple stages of manufacturing scale-up, from prototype builds to pilot production and high-volume manufacturing.
• Experience with high-volume consumer electronics, automotive, aerospace, industrial automation, warehouse robotics, or similarly complex hardware.
• Experience with complex molded and cast metal components.
• Experience with injection mold and die-cast tooling development.
• Experience with tolerance stack-ups and designing assemblies for automated or high-volume assembly.
• Experience working with contract manufacturers and international suppliers.
• Strong CAD experience with a major mechanical design platform.
• Demonstrated ability to provide technical leadership on ambiguous and highly complex mechanical engineering problems.

Kaleidoscope, an Infosys Company, is an equal opportunity employer, and all qualified applicants will receive consideration without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, protected veteran status, spouse of protected veteran, or disability.