Senior Mechanical Engineer

Senior Mechanical EngineerDexmate is building the foundation for physical AI — combining a new generation of robots with a universal Physical AI OS that makes robots as easy to build and deploy as software. Today, robotics is fragmented, slow, and closed: most builders are forced to reinvent the same stack again and again, and most ideas never make it past the prototype stage.Dexmate's mission is to democratize robotics by lowering the barrier to entry, delivering a plug-and-play platform for developers, researchers, and enterprises, and cultivating an open ecosystem that accelerates the evolution of physical AI.Dexmate is looking for a Senior Mechanical Engineer to design, test, and implement key hardware components for their humanoid robot platform. You 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 that spans the full development arc. You will own the transition from working prototype to production-ready design at a contract manufacturer — designing for manufacturability from day one, driving DFM reviews, resolving first-article failures, and ensuring your designs survive the gap between "works in the lab" and "ships at volume." Your designs will be on every unit that leaves the factory.Candidates who have only operated in R&D or prototype-only environments are not a fit for this role.What You'll DoDesign parts and assemblies in 3D CAD that satisfy load conditions, form factor constraints, range-of-motion requirements, and durability targetsDetermine component-level mechanical requirements (stiffness, strength, fatigue, thermal) from system-level functional specsApply analytical methods including FEA, tolerance stack-up, and kinematic analysis before releasing designs for prototyping or productionGenerate accurate 2D drawings with GD&T per ASME Y14.5 appropriate for both prototype and production inspectionBuild prototypes to test assembly, range of motion, wire routing, and integration with adjacent subsystemsDesign and build test stands and fixtures; conduct structured validation testing and document results rigorouslyOwn the prototype-to-production transition: apply DFM/DFA principles from the first design iteration, not as a final step; drive changes required to achieve manufacturability, yield, and cost targetsWork with suppliers to select and qualify parts; inspect first articles, perform root cause analysis on failures, and drive corrective action through to closureConduct DFM/DFA reviews with contract manufacturers; define mechanical acceptance criteria, support tooling bring-up, and stay engaged through production rampDefine and execute structured validation plans including environmental, fatigue, and functional testing to prove out designs before they lock for productionCollaborate closely with electrical engineers on electromechanical integration including motor mounting, sensor placement, wire harness routing, and connector accessContribute to materials selection, surface finishing, and manufacturing process decisions across the robotYou Should Have5+ years of mechanical engineering experience in robotics, industrial automation, automotive, aerospace, or consumer electronics, with at least one product shipped to productionExpert proficiency in 3D CAD (SolidWorks, NX, CATIA, Onshape, or equivalent) for complex parts and assemblies with tight tolerancesMastery of GD&T per ASME Y14.5 and the ability to create production-ready 2D drawingsExperience with actuators and transmission systems including strain-wave (harmonic), planetary, cycloidal gearing, or direct-driveHands-on experience with structural FEA and tolerance stack-up analysis as part of routine design validationProven electromechanical integration experience: motors, sensors, encoders, wire harnesses, and connectors in tight mechanical envelopesDemonstrated ability to take a design from working prototype to production-ready, including DFM iterations, supplier qualification, first-article inspection, and manufacturing yield validationNice to HaveDeep familiarity with manufacturing processes and when to apply each: CNC machining (3- and 5-axis), injection molding, die casting, sheet metal, MIM, investment casting, and surface finishing; understanding of tradeoffs across cost, tolerance, lead time, and volumeDirect experience working with contract manufacturers on DFM reviews, tooling bring-up, first-article inspection, and yield improvementHands-on prototyping experience with rapid fabrication methods (FDM/SLA/SLS, CNC soft tooling, urethane casting) and inspection equipment including CMM, optical comparators, and CT scanningExperience with thermal design and heat dissipation in compact electromechanical systemsBackground in reliability engineering: fatigue analysis, HALT/HASS, or accelerated life testingWire harness design experienceProficiency with simulation tools beyond FEA: CFD, multi-body dynamics (Adams, Simscape), or kinematic simulationFamiliarity with functional safety requirements for mechanisms operating near humansCompensationBase Salary: $120,000 - $300,000, depending on experience, plus equity.