Senior Gear Design Engineer

We are looking for a Senior Gear Design Engineer to own gear and transmission design for our humanoid robot's hands — some of the most power-dense, space-constrained actuators in the world. You will take gear trains from first-principles sizing through validation and into mass manufacturing, defining how our robot grasps and manipulates the world.

Responsibilities:

Own gear design end-to-end: system-level sizing, macro and micro geometry definition, rating and life analysis, prototyping, validation, and ramp to mass production.

Perform gear sizing, contact/bending stress analysis, and micro-geometry optimization (profile and lead modifications) in KISSsoft to meet efficiency, durability, backlash, and NVH targets.

Design gears, shafts, and transmission assemblies in 3D CAD (CATIA) that satisfy extreme packaging, load, and durability requirements of a high-DOF robotic hand.

Define gear manufacturing strategy — cutting, grinding, powder metal, MIM, or plastics — and drive DFM with suppliers from first articles through high-volume production.

Generate accurate 2D drawings with gear data tables and GD&T per ASME Y14.5, and define inspection and metrology plans for incoming quality.

Build and run test rigs to characterize efficiency, backlash, wear, and fatigue life; correlate test data back to analytical models.

Collaborate closely with actuator, structures, EE, and manufacturing teams — proactively identifying risks, driving decisions, and unblocking the program without waiting to be asked.

Requirements:

7+ years of experience designing gears and geared transmissions.

Bachelor's or Master's Degree in Mechanical Engineering, Robotics, Mechatronics, or similar field.

Demonstrated ownership of complete gear designs from initial sizing through mass manufacturing.

Proficiency in KISSsoft (or equivalent) for gear rating, contact analysis, and micro-geometry optimization.

Proficiency in CATIA (or equivalent high-end 3D CAD) for complex geometry and large assemblies.

Working knowledge of AGMA/ISO gear rating standards, gear metrology, and tolerancing.

Experience with gear manufacturing processes (hobbing, shaping, skiving, grinding, powder metal, MIM, or injection molding) and supplier development.

A strong team player with a high sense of agency — you take ownership of outcomes, communicate openly, and elevate the people around you.

Bonus Qualifications:

Experience with small-module, high-ratio, or high-power-density gearing (planetary, cycloidal, or strain wave).

Experience in robotics, surgical devices, aerospace actuation, or automotive e-drive transmissions.

Familiarity with lubrication selection, grease DOE, and tribology for compact gearboxes.

Experience with fatigue modeling, bearing life characterization, and accelerated life testing.

Experience taking a product through NPI builds (EVT/DVT/PVT) and FATP at volume.

The US base salary range for this full-time position is $160,000 to $250,000 per year.

The pay offered for this position may vary based on several individual factors, including job-related knowledge, skills, and experience. The total compensation package may also include additional components/benefits depending on the specific role. This information will be shared if an employment offer is extended.