Senior/Principal Mechanical Design Engineer

Kaleidoscope; Boston (MA); On-site; USD 100,000 - 200,000; Full time

Job summary

Kaleidoscope in the United States seeks a Senior/Principal Mechanical Design Engineer to lead end-to-end mechanical design and scale-up of robotic modules from concept through high-volume production.

The role focuses on electromechanical systems, DFMA, and manufacturability, with cross-functional collaboration across manufacturing, QA, and suppliers to deliver reliable, scalable hardware.

Qualifications

• Bachelor's or Master's degree in Mechanical Engineering, Mechatronics, or a related engineering discipline.

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 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.
• Perform thickness/scale-up considerations, tooling and manufacturing process alignment.
• 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 across future robotic products.

Skills

End-to-end mechanical design

Electromechanical systems

DFM

DFA

GD&T

Tolerance analysis

Material selection

Structural design

High-volume manufacturing

Cross-functional collaboration

Education

Bachelor's or Master's in Mechanical Engineering

Mechatronics or related field

Tools

CAD

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

Senior/Principal Mechanical Design Engineer

Salary Range: $100,000.00 To $200,000.00 Annually

Senior/Principal Mechanical Design Engineer

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 theend-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 theend-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 complexelectromechanical robotic products.
• Design components, assemblies, and mechanisms with consideration for performance, reliability, manufacturability, cost, and high-volume production.
• ApplyDesign for Manufacturing (DFM) andDesign 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 intofull-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 complexelectromechanical systems and assemblies.
• Demonstrated experience taking ownership of mechanical design at themodule or system level, rather than exclusively designing individual components.
• Deep understanding ofDesign 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.