Sr Mechanical Engineer, Fan and Duct Design

Figure-posted 1 day ago
$160,000 - $200,000/Yr
Full-time • Mid Level
San Jose, CA
251-500 employees
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Figure is an AI robotics company developing autonomous general-purpose humanoid robots. The goal of the company is to ship humanoid robots with human level intelligence. Its robots are engineered to perform a variety of tasks in the home and commercial markets. Figure is headquartered in San Jose, CA. We are seeking a Senior Mechanical Engineer focused on Fan and Duct Design to own the end-to-end development of the robot’s airflow systems from early impeller geometry prototypes to production-ready assemblies released to manufacturing.

  • Own the mechanical design of the robot’s fan assemblies: impellers, housings, ducts, diffusers, seals, shrouds, baffles, and mounting structures.
  • Translate CFD-engineered impeller geometry into fully detailed, moldable components with proper drafts, ribs, gates, cooling channels, and tooling strategies.
  • Develop manufacturable plastic parts (injection-molded), metal components, and hybrid structures for quiet, efficient airflow.
  • Select, qualify, and integrate fan motors including BLDC, slotless motors, PMSMs, or custom motor architectures depending on system targets.
  • Collaborate with motor vendors and CMs to determine winding specs, bearings, back-EMF constants, and long-life design constraints with additional support from the Figure motor team
  • Support thermal and acoustic engineers by designing test fixtures, running airflow tests, and validating fan performance.
  • Own iterative cycles: prototype → measure → redesign → retest.
  • Drive supplier engagement on tooling, gating, draft strategies, warpage control, and tolerance analyses.
  • Partner with GSM and CMs to close out DFM, tooling release, mold trials, and FAIs.
  • Create drawing packages, GD&T, BOMs, and assembly instructions for production.
  • Collaborate with CFD, thermal, acoustics, system architecture, IDand manufacturing teams to converge on a highly optimized fan system.
  • Work with global suppliers to evaluate materials, molding processes, motor options, and assembly methods.
  • Provide hands-on build support for engineering units and early factory runs.
  • 5+ years experience in mechanical engineering, electromechanical design, turbomachinery components, or similar.
  • Bachelor’s or Master’s in Mechanical Engineering, Mechatronics, Aerospace, or related field.
  • Expert in 3D CAD modeling and surfacing; comfort with complex geometries derived from CFD.
  • Deep understanding of mechanical design for airflow systems: fans, ducts, impellers, shrouds, or related components.
  • Experience turning CFD geometry into manufacturable CAD suitable for tooling.
  • Familiar with experimental methods for measuring flow, pressure, and acoustic performance.
  • Strong DFM knowledge for injection molding, tooling, and assembly.
  • Ability to write clear documentation, test plans, and release packages.
  • Experience with small BLDC fan motors, custom motor sourcing, or electromechanical integration.
  • Background in acoustics, noise reduction, vibration isolation, or fan blade noise characterization.
  • Experience with high-volume plastic injection molding and tool releases.
  • CATIA V6 experience.
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