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.

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.

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.

The Staff Mechanical Design Engineer will lead mechanical and plumbing system designs, ensure code compliance, participate in field construction, and collaborate across disciplines.

Lead end-to-end mechanical design of electric motors and related assemblies for autonomous aircraft, from requirements through production. Design rotor-stator assemblies, housings, cooling, enclosures, and interfaces; perform FEA/CAE, thermal and rotor-dynamics analysis; develop production CAD, GD&T drawings, test plans, prototypes, and supplier readiness; and drive manufacturability, reliability, and cost-down efforts.

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.

Design and develop Plasma-Enhanced CVD reactor systems and components, lead prototyping and manufacturing, produce drawings, collaborate with vendors and teams, troubleshoot and improve reactor performance and yield.

Lead mechanical design of battery and power electronics hardware from requirements through production. Design enclosures, busbars, and power distribution components; perform structural, thermal, vibration, EMI analyses; create production CAD, drawings, and GD&T; plan and execute environmental and reliability testing; qualify suppliers and support manufacturing handoff; mentor engineers and provide cross-functional technical leadership.

Design, prototype, and iterate mechanical subsystems from concept to working hardware. Use CAD, perform hand calculations and FEA as needed, select materials and tolerances, build prototypes with 3D printing and CNC, and integrate mechanical designs with electronics, motors, sensors, and control systems in an on-site San Francisco environment.

Design, prototype, and scale durable robots: create parts and assemblies in Onshape, build and test prototypes, ensure serviceability/safety, produce engineering drawings, source parts with suppliers, and design qualification and end-of-line tests while supporting production.

Collaborate on mechanical designs for data center systems, validating performance, overseeing construction, and ensuring designs meet quality benchmarks.

The Mechanical Design Engineer will lead sustaining engineering, develop next-gen products, manage prototyping, create CAD models, and document designs.

Lead mechanical engineering evaluations for data center opportunities, assessing HVAC, cooling, chiller, CRAH/CRAC, liquid cooling, and critical equipment systems. Conduct facility due diligence, validate capacity and design assumptions, evaluate vendors and deployment risks, and provide feasibility and Go/No-Go recommendations. Support mechanical design strategies, equipment selection, commissioning, and construction readiness while partnering with engineering teams, consultants, and vendors to establish scalable standards for hyperscale and AI infrastructure.

Lead design and analysis of precision electro-mechanical subsystems for a metal 3D printer, produce parts and assemblies, manage BOM/revision control and sourcing, perform rapid prototyping and metrology-based testing, maintain machine tools, and collaborate across mechanical, electrical, materials, and software teams to move designs into manufacturing.

Lead structural design for utility-scale battery enclosures, using FEA (Ansys) and hand calculations to optimize for performance, weatherproofing, manufacturability, and cost. Drive design-to-production for sheet metal and weldment assemblies, validate via test correlation, present findings, and perform failure root-cause analysis.

Design and develop sheet metal assemblies, weldments, and sealing systems for utility-scale battery enclosures. Perform FEA-driven structural analysis (Ansys and hand calculations), collaborate with test and CAE teams to validate designs, drive manufacturability for high-volume production, and support failure analysis and design reviews. Travel to vendor sites up to 20%.

The role involves designing electromechanical solutions for telecom systems, focusing on mechanical designs, thermal management, and product development. Responsibilities include overseeing prototype builds, collaborating with teams, and applying best practices in engineering.

Responsible for designing and developing vehicle body structures for an autonomous ATV, ensuring performance across extreme conditions using CAD and FEA tools, and collaborating with team members on integrated vehicle architectures.

Lead structural analysis using Ansys FEA and hand calculations for utility-scale energy storage hardware. Define analysis methodology and pass/fail criteria, create calculation tools, validate designs through testing and FEA correlation, perform failure root-cause analysis, and collaborate with designers to optimize for manufacturability, cost, weight, and reliability.

Lead propulsion hardware design from concept through flight qualification and integration. Perform design trade studies, detailed CAD design, structural/thermal/fluid analyses, prototype assembly and tooling, test hardware, analyze data, diagnose issues, and present design reviews.