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.