Senior Mechanical Engineer

Bots Unlimited•San Antonio, TX

2h•Hybrid

About The Position

We are seeking a highly experienced Senior Mechanical Engineer to lead the end-to-end mechanical development of our robotics and drone hardware. This is a high-impact, hybrid role requiring a rare combination of expertise: you will own the mechanical design for both high-performance electromechanical subsystems (brushless DC motors, rotating assemblies) and product enclosures (precision plastics, protective sleeves, and ruggedized housings). We are looking for self-managed, Type A personalities: people who thrive in fast-moving environments, can work independently, and push projects forward without constant direction. Your work will directly enable our Bots Unlimited product lineup, turning complex motor and enclosure concepts into production-ready hardware that meets tight tolerance, thermal, and aesthetic requirements. This is a hands-on, onsite role based in San Antonio, TX. You will work closely with electrical, test, and manufacturing teams in our lab environment to build, validate, and iterate on real hardware. Our team operates at startup speed, and you’ll be expected to contribute directly to hardware that ships to customers on aggressive timelines.

Requirements

Education: Bachelor’s or Master’s degree in Mechanical Engineering or equivalent experience.
Experience: 5–10+ years of professional mechanical design experience.
Dual Expertise: Proven track record designing both high-volume mold injected plastic products (e.g., consumer electronics, phone cases, rugged enclosures) and rotating equipment/motors.
CAD Mastery: Expert proficiency in 3D CAD (SolidWorks, Autodesk Inventor, or Creo) with the ability to manage complex assemblies and detailed 2D drawings.
Manufacturing Knowledge: Deep understanding of injection molding (tooling, draft, sink, gates) and CNC machining processes.
Technical Standards: Solid understanding of GD&T, tolerance analysis, and material properties (polymers, resins, and alloys).
Systems Tools: Experience using PLM/PDM systems (e.g., Duro, Windchill) to manage part revisions and BOMs.
Hands-on Skills: Proficiency with calipers, micrometers, and lab tools for physical prototype validation and fit/clearance checks.
Communication: Excellent verbal and written skills; ability to work onsite in San Antonio and travel periodically for vendor visits or product milestones.

Nice To Haves

Prior experience with brushless DC (BLDC) motors or electromechanical actuators.
Experience in overmolding, ultrasonic welding, or advanced plastic finishing processes.
Background in rotor balancing, vibration analysis, or thermal management for electronics.
Previous experience with supplier sourcing and DFM for mass production.
Familiarity with rotating systems safety standards and impact resistance for mobile devices.

Responsibilities

Plastics & Enclosures: Lead the design and engineering of high-precision mold injected plastic enclosures, including cell phone-style sleeves, protective cases, and internal mounting structures.
Electromechanical Design: Develop 3D CAD models for motors, housings, rotor/stator sub-assemblies, shafts, and bearings.
Lifecycle Management: Own the full design lifecycle from concept through detailed CAD modeling, drawing release, and manufacturing support.
Technical Documentation: Produce full mechanical drawings including GD&T, tolerance stacks, material specifications, and surface-finish details for both machined metal and injection-molded parts.
PLM & Data Management: Manage and maintain mechanical data, part numbers, and revision control within the Duro PLM system (or equivalent).
DFM/DFMA: Perform rigorous reviews to ensure designs are optimized for injection molding, CNC machining, and rapid assembly.
Vendor Coordination: Interface with global vendors to issue RFQs, review vendor drawings, negotiate tolerances, and manage prototype/production builds.
Validation & Testing: Lead mechanical validation (vibration, thermal, drop testing, and lifecycle durability) and record physical test data.