Top Mechanical Design Engineer Jobs in San Francisco Bay Area, CA

Design and develop robotic actuators, including transmissions, motor integration, structural packages, bearings, sealing, and thermal systems. Define and run life testing using fleet-derived load spectra, perform teardown analysis, and establish evidence-based design margins. Collaborate on in-house assembly, calibration, end-of-line testing, and actuator performance roadmaps. The role requires precision mechanical design, geartrain analysis, manufacturing and DFM expertise, CAD, FEA, tolerance analysis, GD&T, fatigue, and thermal design experience.

Design and own mechanical subsystems for autonomous machines from concept through prototype and testing. Create CAD models, perform calculations and FEA, select materials and manufacturing methods, fabricate hardware using workshop tools, and integrate mechanisms with drive, sensing, and controls components. Collaborate with electrical, software, and robotics engineers to deliver complete field-ready systems.

Design and verify mechanical components for medium-voltage mobile power transformers and substations. Create 3D core and coil designs, shop drawings, connection diagrams, woodwork structures, and lead routing using EAP and Autodesk Inventor. Generate ERP material usage files, support production by resolving design issues, and provide technical guidance. Future responsibilities include external transformer and tank designs, plus programming plasma and wood routing machines.

Own high-fidelity CFD and transient thermal modeling for iron-air energy storage systems, spanning electrochemical cells to containerized systems. Validate simulations against test data, automate optimization workflows, analyze fluid routing and cooling efficiency, resolve thermal-fluid integration issues, select modeling methods, standardize workflows, and develop custom tools to address simulation limitations. Translate complex modeling results into system-level design requirements and guide multidisciplinary engineering decisions.

Design, evaluate, procure, assemble, and test spacecraft structures, brackets, and mechanisms. Develop component and system requirements, perform mechanical and thermal analyses, integrate hardware, and improve build procedures. The role also supports recruiting and hiring. Requires hands-on mechanical design experience, CAD and GD&T proficiency, and familiarity with mechanical and thermal analysis in hardware development.

Own the complete lifecycle of spacecraft mechanical subsystems, including design, analysis, requirements development, integration, testing, and hardware delivery. Develop spaceflight structures and mechanisms, manage subsystem schedules and interfaces, establish design practices, and collaborate with assembly and test teams. Mentor junior engineers and support recruiting. The role requires aerospace hardware design experience, CAD expertise, GD&T, manufacturability knowledge, and prior satellite flight hardware experience.

Designs, fabricates, commissions, validates, and improves mechanical crash-safety test equipment for batteries and aircraft hardware. Responsibilities include structural fixtures, containment systems, high-force actuation, engineering analysis, CAD documentation, operator safety systems, instrumentation integration, troubleshooting, validation testing, and supplier coordination.

Develop thermal-hydraulic models for scientific apparatus using ASME B31.3-2022 for installation at a research reactor. Perform steady-state and transient temperature modeling, work independently, and coordinate with EPC contractors and vendors on costs and budgets. The role is remote, part-time, and temporary, with at least four required site visits to State College, Pennsylvania. U.S. citizenship, background screening, drug-free status, and references are required.

Designs mechanical and electromechanical test fixtures, tooling, and related hardware for optical networking products. Responsibilities include CAD modeling, engineering drawings, BOMs, configuration-controlled documentation, engineering analysis, tolerance studies, fabrication support, assembly, troubleshooting, validation, and deployment. The role collaborates with engineers, technicians, suppliers, and manufacturing partners to deliver reliable, manufacturable solutions throughout the product development lifecycle.

Lead the architecture, hydraulic design, documentation, integration, manufacturing readiness, controls coordination, and commissioning of liquid-cooling and mechanical distribution systems for modular AI data centers. Own P&IDs, calculations, equipment and valve schedules, interfaces, standards, and performance validation. Collaborate with thermal, electrical, controls, manufacturing, commissioning, supply chain, OEM, and field teams to create scalable, serviceable, repeatable systems for deployment across multiple sites.

Design and develop high-temperature mechanical components, assemblies, and systems from concept through production. Perform FEA, thermal and fluid-flow analysis, FMEA, GD&T, and tolerance stack-ups. Integrate sensors, instrumentation, and cable routing while collaborating with electrical and controls teams. Lead prototyping, testing, design reviews, supplier documentation, scheduling, and cross-functional progress reporting. The role is onsite in Alameda with up to 10% travel.

Own the complete thermal system for medium-voltage solid-state power conversion products, from architecture and modeling through CAD, CFD, prototyping, validation, manufacturing, and production. Lead concept selection, thermal routing, DFM/DFA, testing, troubleshooting, and technical direction for junior engineers. Collaborate cross-functionally with mechanical, electrical, manufacturing, quality, supplier, and factory teams to solve novel thermal engineering challenges.

Design and own mechanical robotic subsystems from concept through prototyping, testing, iteration, and production. Responsibilities include CAD modeling, material and tolerance selection, design for manufacturability, hands-on prototype fabrication using 3D printing and CNC machining, and integration of motors, sensors, electronics, and actuators into robotic arms and mobile bases. The role requires close collaboration with hardware teams to develop reliable systems for data center operations.

Design and deliver mechanical and fluid system components from concept through production and flight. Perform trade studies, detailed CAD designs, and structural/thermal/fluid analyses. Collaborate with propulsion, structures, avionics, controls, and manufacturing teams, work with suppliers, develop and run hardware test plans, support prototyping, vehicle builds, ground and flight testing, and participate in technical reviews and safety/hazard analyses.

Lead mechanical design for consumer electromechanical products from concept through production. Responsibilities include CAD modeling, prototyping, testing, thermal/fluid/structural analysis, cross-functional collaboration, DFM/DFA, tolerance analysis, and manufacturing ramp support in Asia. The role requires designing plastic, metal, and soft goods components integrated with sensors and actuators, supporting high-volume manufacturing, and traveling to China as needed.

Designs and validates stator and rotor mechanical components for advanced robotic motors. Responsibilities include CAD and drawing release, tolerance analysis, lamination and bobbin development, fixture design, prototype fabrication and troubleshooting, metrology, winding interface development, and establishing repeatable low-volume build processes with work instructions and inspection standards. Partners with electromagnetic, electrical, manufacturing, and test engineers to optimize performance, manufacturability, and reliability.

Own the design and delivery of automated factory equipment from concept through production acceptance. Lead cross-functional mechanical, controls, software, and manufacturing teams; define requirements, conduct design reviews, manage phase gates, and ensure equipment meets timeline, cost, reliability, and performance goals. Partner with factory development and production teams to deploy turnkey systems. The role requires mechanical CAD expertise, automated equipment development experience, and collaboration across engineering and manufacturing functions.

Designs and develops pharmaceutical drug-delivery devices and platforms using CAD, prototyping, testing, tolerance analysis, and Design for Manufacturing principles. Collaborates with internal teams, external consultants, CROs, and manufacturing partners to troubleshoot products, support design controls, build intellectual property, and transfer devices into production. Manages project budgets and timelines while serving as a technical resource for cross-functional teams.

Own the system-level design of welded steel drone-delivery towers and subassemblies, including structural components, mechanisms, and electronics integration. Apply mechanical fundamentals, hand calculations, FEA, CAD, prototyping, and testing to develop reliable products. Collaborate with electrical, software, civil, NPI, and supply chain teams to transition designs into production and field deployment. Maintain BOMs, release parts, create build documentation, support contract manufacturers, and periodically visit customers and suppliers.

Lead electromechanical design for high-voltage battery power systems including busbars, cables, harnesses, isolation, grounding, enclosures, and safety interlocks. Perform thermal, structural, and manufacturability analyses, run RCAs, create drawings and manufacturing instructions, and take designs from concept to high-volume production while collaborating across engineering teams and supporting test-stand safety.

Design custom industrial machinery, automation equipment, robotic tooling, fixtures, and mechanical systems from concept through commissioning. Create CAD models, manufacturing drawings, bills of materials, and engineering documentation using GD&T and design-for-manufacturing principles. Support fabrication, machining, welding, assembly, prototyping, testing, troubleshooting, and continuous improvement while collaborating with manufacturing, controls, suppliers, project management, and technicians.

Leads mechanical design and validation of high-temperature insulation systems, structural interfaces, seals, and thermomechanical components operating up to 1500 °C. Performs thermal analysis, FEA, FMEA, testing, and experiments; manages CAD and PLM documentation; develops requirements; supports prototyping, manufacturing, suppliers, and production improvements; and provides technical leadership through design reviews and cross-functional project execution.

Lead mechanical process design for water and wastewater projects: develop basis of design, equipment sizing/selection, construction documents, specifications, hydraulic analyses, cost estimates, discipline coordination, project management, business development, mentoring, and quality control.

Lead mechanical development of automated ground systems from concept to field deployment. Design structures, precision mechanisms, electromechanical assemblies; prototype, validate, and ensure manufacturability, reliability, safety, and operational usability while partnering cross-functionally and with suppliers.

Design and deliver mechanical subsystems from concept through production: translate requirements into CAD, drawings, BOMs, and verification plans; lead prototyping, FEA and first-principles analysis, test campaigns, supplier handoffs, and cross-functional integration to meet mass, life, and reliability targets.