Senior Mechanical Engineer

About Dexmate

Dexmate is building the foundation for physical AI by combining a new generation of robots with a universal Physical AI OS, making robots easier to build and deploy. The company is focused on lowering the barrier to entry in robotics through a plug-and-play platform for developers, researchers, and enterprises.

The Role

Dexmate is looking for a Senior Mechanical Engineer to design, test, and implement key hardware components for its humanoid robot platform. This role will own mechanical subsystems end-to-end, from requirements definition through 3D CAD, prototype build, supplier qualification, first-article inspection, and production release.

This is a hands-on role spanning the full development lifecycle from prototype to production-ready design. The Senior Mechanical Engineer will drive DFM/DFA from the earliest design stages, resolve first-article failures, and ensure designs can successfully transition from lab prototypes to scalable production.

Responsibilities

- Design parts and assemblies in 3D CAD to meet load conditions, form-factor constraints, range-of-motion requirements, and durability targets.
- Define component-level mechanical requirements including stiffness, strength, fatigue, and thermal performance from system-level specifications.
- Apply FEA, tolerance stack-up analysis, and kinematic analysis prior to releasing designs for prototype or production.
- Generate production-ready 2D drawings with GD&T per ASME Y14.5.
- Build prototypes to evaluate assembly, range of motion, wire routing, and adjacent subsystem integration.
- Design and build test stands and fixtures.
- Conduct structured validation testing and document results.
- Own the prototype-to-production transition for assigned mechanical subsystems.
- Apply DFM/DFA principles throughout the design lifecycle.
- Drive design changes required to achieve manufacturability, yield, and cost targets.
- Work with suppliers to select and qualify parts.
- Inspect first articles, perform root-cause analysis on failures, and drive corrective actions through closure.
- Conduct DFM/DFA reviews with contract manufacturers.
- Define mechanical acceptance criteria and support tooling bring-up and production ramp.
- Develop and execute environmental, fatigue, and functional validation plans.
- Collaborate with electrical engineers on motor mounting, sensor placement, wire-harness routing, connector access, and electromechanical integration.
- Contribute to material selection, surface finishing, and manufacturing process decisions across the robot.

. Skillset Required: Must-haves: - 5+ years of mechanical engineering experience in robotics, industrial automation, automotive, aerospace, or consumer electronics - At least one product successfully shipped to production - Expert proficiency in 3D CAD such as SolidWorks, NX, CATIA, Onshape, or equivalent - Mastery of GD&T per ASME Y14.5 - Ability to create production-ready 2D drawings - Experience with actuators and transmission systems including strain-wave/harmonic, planetary, cycloidal, or direct-drive systems - Hands-on experience with structural FEA and tolerance stack-up analysis - Proven electromechanical integration experience with motors, sensors, encoders, wire harnesses, and connectors - Demonstrated ability to take a mechanical design from working prototype to production-ready hardware - Experience with DFM iterations, supplier qualification, first-article inspection, and manufacturing yield validation Required Skills: - Mechanical engineering - Robotics hardware development - Complex mechanical subsystem design - 3D CAD - SolidWorks, NX, CATIA, Onshape, or equivalent - GD&T - ASME Y14.5 - Production-ready 2D drawings - Structural FEA - Tolerance stack-up analysis - Kinematic analysis - Actuator design and integration - Harmonic / strain-wave gearing - Planetary gearing - Cycloidal gearing - Direct-drive systems - Electromechanical integration - Motor and sensor integration - Encoder integration - Wire-harness and connector integration - Prototype development - Design validation - Test fixture development - DFM and DFA - Supplier qualification - First-article inspection - Root-cause analysis - Corrective actions - Manufacturing yield validation - Contract manufacturer collaboration - Tooling bring-up - Production release and ramp - Material and surface-finish selection Desired Skills: - CNC machining including 3-axis and 5-axis - Injection molding - Die casting - Sheet metal fabrication - Metal injection molding (MIM) - Investment casting - Surface finishing including anodizing, PVD, and powder coating - Experience working directly with contract manufacturers - Rapid prototyping using FDM, SLA, or SLS 3D printing - CNC soft tooling - Urethane casting - First-article inspection using CMM, optical comparators, or CT scanning - Thermal design for compact electromechanical systems - Reliability engineering - Fatigue analysis - HALT/HASS or accelerated life testing - Wire-harness design - CFD experience - Multi-body dynamics using Adams, Simscape, or similar tools - Kinematic simulation - Familiarity with functional safety requirements for mechanisms operating near humans