Mechanical Design Engineer, Body Structures, Frame (Autonomous Vehicle Team)

Foundation•San Francisco, CA

132d•$115,000 - $150,000

About The Position

Design and develop the vehicle body and structural architecture to perform across extreme multi-environment conditions—from high-impact off-road shock loads to full water submersion and long-term vibration fatigue. Own structural performance from concept through prototype, using FEA and simulation-driven design to rapidly iterate on geometries, reduce material usage, and accelerate development cycles. Engineer frame systems that achieve an optimized stiffness-to-weight ratio through thoughtful material selection across steel alloys, aluminum extrusions, and composite structures. Drive rapid prototyping efforts by translating CAD designs into physical builds using CNC machining, welding, sheet metal fabrication, and additive manufacturing. Design robust joints and interfaces that account for thermal expansion, corrosion between dissimilar metals, and long-term serviceability in harsh environments. Collaborate closely with robotics, suspension, and systems engineering to co-develop structural hardpoints, mounting interfaces, and routing pathways as part of a fully integrated vehicle architecture.

Requirements

5+ years of hands-on experience designing and building structural mechanical systems
Strong proficiency in 3D CAD (SolidWorks, CATIA, NX, or similar), with a disciplined approach to assemblies, tolerancing, and managing complex multi-part systems
Experience using FEA and simulation tools (ANSYS, ADAMS, or similar) to inform design decisions, including structural, fatigue, and modal analysis
Practical experience with fabrication processes such as welding, machining, and sheet metal—comfortable working between CAD and the shop floor
Solid understanding of materials and their trade-offs in structural applications, including strength, fatigue, corrosion resistance, and weight
Experience designing for harsh environments, including water exposure, corrosion, and sealing of structural systems
Ability to think in systems—designing structures that integrate cleanly with actuators, wiring, fluid systems, and sensors from the outset

Responsibilities

Design and develop the vehicle body and structural architecture to perform across extreme multi-environment conditions
Own structural performance from concept through prototype, using FEA and simulation-driven design
Engineer frame systems that achieve an optimized stiffness-to-weight ratio
Drive rapid prototyping efforts by translating CAD designs into physical builds
Design robust joints and interfaces that account for thermal expansion, corrosion between dissimilar metals, and long-term serviceability in harsh environments
Collaborate closely with robotics, suspension, and systems engineering to co-develop structural hardpoints, mounting interfaces, and routing pathways